Shell EP ASIA PACIFIC (EPA)
Production Directorate
SMEP LIFTING AND HOISTING MANUAL SMEP.EP200802258279 Code of Practice Business Control Document – Company Standard Restricted to Shell Personnel Only
Page 1 of 247
DOCUMENT HISTORY Custodian
William MacDonald
Export Compliance Control No.
No US Content
Type
Business Control Document – Company Standard
REVISION CHANGE DETAILS REV.
Location of Change
0.1
Description of Change
New Issue
This document will be maintained live on the Shell EPA intranet site.
The web-based document
will be the controlled version and revision announcements will be distributed via e-mail to relevant parties and published on the web.
Copies or extracts of this document, which have
been downloaded from the website, are uncontrolled copies and cannot be guaranteed to be the latest version.
DISCLAIMER The relationships shown in this document are for EPA Region organizational maintenance and planning purposes and are not intended to create legal or corporate authority incompatible with or superseding the underlying corporate governance and structure of participating companies, including for example, authorities of the board of directors, individual directors or executive officers of any particular company.
Page 2 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
TABLE OF CONTENTS 1.0
PREFACE. ............................................................................................... 15
1.1
Possible Reasons For Accidents ................................................................... 15
1.1.1
Contributory Factors ................................................................................. 15
1.1.2
Operator Error ........................................................................................ 15
1.1.3
Equipment Failure .................................................................................... 15
1.1.4
Safe System of Work ................................................................................ 16
1.1.5
Requirements of a Safe System of Work. ....................................................... 16
2.0 2.1 3.0
Purpose ................................................................................................. 18 Scope .................................................................................................... 18 Certification ........................................................................................... 19
3.1
Introduction ............................................................................................ 19
3.2
Certification With New Lifting Equipment ...................................................... 19
3.2.1
Inspection Certificate ................................................................................ 19
3.2.2
Operating and Maintenance Instructions ....................................................... 19
3.3
Certification of Existing Lifting Equipment ..................................................... 19
3.4
Retention Period for Certificates and Reports. ................................................ 19
3.4.1
Inspection Certificates............................................................................... 19
3.4.2
Thorough Examination Certificates ............................................................... 20
4.0 4.1 5.0
Maintenance of Lifting Equipment ................................................................ 21 Introduction ............................................................................................ 21 Marking of Lifting Equipment ...................................................................... 22
5.1
Requirements .......................................................................................... 22
5.2
Working Load Limit (WLL)/ Safe Working Load (SWL) ...................................... 22
5.2.1
Safe Working Load (SWL) Mark .................................................................. 22
5.2.2
Working Load Limit (WLL) Mark .................................................................. 22
5.2.3
Variable WLL or SWL ................................................................................ 22
5.2.4
De-rating ............................................................................................... 23
5.2.5
Lifting Equipment assembly ........................................................................ 23
5.2.6
Lifting Accessory Configurations ................................................................. 23
5.2.7
Accessories- Other Factors ......................................................................... 23
5.2.8
Lifting Equipment for Lifting Persons ............................................................ 23
5.2.9
Gangways .............................................................................................. 23
5.2.10 6.0 6.1 7.0 7.1
Equipment Identity Marking .................................................................... 23 Lifting Equipment Colour Codes .................................................................. 24 Lifting Equipment Colour Coding System ....................................................... 24 Training of Personnel ................................................................................ 25 Training Responsibilities............................................................................ 25
Page 3 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
7.2
Training ................................................................................................. 25
7.2.1
Additional Training .................................................................................. 25
7.2.2
Training for New and Inexperienced Personnel ............................................... 25
7.2.3
Personnel Under Training........................................................................... 25
7.2.4
Qualification Updates ............................................................................... 25
8.0
Planning, Definitions and Execution of Lifts ................................................... 26
8.1
Purpose ................................................................................................. 26
8.2
Scope .................................................................................................... 26
8.3
Responsibilities ....................................................................................... 26
8.4
Correct Use ............................................................................................ 26
8.5
Safety Margin ......................................................................................... 26
8.6
Controlling Access to the Lift Area............................................................... 26
8.7
Risk Assessment ....................................................................................... 26
8.7.1
Lift Plan/JSA ........................................................................................... 26
8.7.2
Risk Matrix ............................................................................................. 27
8.7.3
10 Questions For a SAFE Lift ...................................................................... 28
8.8
Lift Categorisation ................................................................................... 28
8.8.1
Routine Lifts ............................................................................................ 28
8.8.2
Routine Lift ............................................................................................. 28
8.8.3
Non-Routine – SIMPLE ............................................................................... 30
8.8.4
Non-Routine – COMPLICATED ..................................................................... 31
8.8.5
Non-Routine – COMPLEX ........................................................................... 31
8.8.6
Non-Routine – HEAVY ............................................................................... 33
8.9
Execution ............................................................................................... 33
8.9.1
Permits .................................................................................................. 33
8.9.2
Pre-lift Meetings (Toolbox Talk)................................................................... 33
8.9.3
Conducting the Lifting Operation................................................................. 33
9.0
Personnel Lifting ...................................................................................... 34
9.1
Purpose ................................................................................................. 34
9.2
Scope .................................................................................................... 35
9.3
Authority................................................................................................ 35
9.4
Prerequisites ........................................................................................... 35
9.5
Objectives .............................................................................................. 36
9.6
Procedures ............................................................................................. 36
9.7
Defined Cases ......................................................................................... 36
9.8
Emergency Conditions ............................................................................... 36
9.9
Risk Assessment ....................................................................................... 36
9.10
Other Considerations ................................................................................ 37
9.11
Criteria.................................................................................................. 37
Page 4 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
9.11.1
Crane Suitability .................................................................................. 37
9.11.2
Personnel Transfer Carrier ...................................................................... 37
9.11.3
Vessel Suitability .................................................................................. 38
9.11.4
Take-off and landing area ...................................................................... 38
9.12
Environmental ......................................................................................... 39
9.12.1
Weather ............................................................................................ 39
9.12.2
Visibility ............................................................................................. 39
9.12.3
Daylight ............................................................................................. 39
9.12.4
Rainfall and Electrical Storms .................................................................. 40
9.12.5
Communications ................................................................................... 40
9.13
Personnel ............................................................................................... 40
9.13.1
Crane or Winch Operator ....................................................................... 40
9.13.2
Banksman ........................................................................................... 40
9.13.3
Assisting Personnel ............................................................................... 40
9.13.4
Personnel Transferring by Carrier ............................................................ 40
9.14
Bags ..................................................................................................... 41
9.15
Toolbox Talk ........................................................................................... 41
9.16
Recovery Arrangements ............................................................................. 41
9.17
Vessel Propellers...................................................................................... 41
9.18
Planned Maintenance ................................................................................ 41
9.19
Administration and Operational Duties. ........................................................ 41
9.19.1
SMEP Site Representative ....................................................................... 42
9.19.2
Master of the Vessel .............................................................................. 42
9.19.3
Banksman and/or Deck Foreman .............................................................. 43
9.19.4
Crane Operator .................................................................................... 43
9.19.5
Riggers/Deck Hands .............................................................................. 43
9.19.6
Personnel Transferring ........................................................................... 44
9.19.7
Crane owner’s Requirements ................................................................... 44
9.19.8
General Precautions .............................................................................. 44
9.19.9
Pre-Use Inspection.................................................................................... 45
9.19.10
Trial Lifts ............................................................................................ 45
9.20
Man Riding (drilling operations) ................................................................. 45
9.20.1
Winches for Man Riding ............................................................................ 46
10.0
Suspended Work Baskets (Cranes) ............................................................... 48
10.1
Requirements .......................................................................................... 48
10.2
Equipment .............................................................................................. 48
10.3
Personnel ............................................................................................... 48
10.4
Personnel Engaged in Suspended Work Basket Activities (Onshore Only) ............. 49
10.4.1
Authority ............................................................................................ 49
Page 5 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
10.4.2
Prerequisites ....................................................................................... 49
10.4.3
Risk Assessment................................................................................... 49
10.4.4
Other Considerations ............................................................................ 50
10.5
Criteria.................................................................................................. 50
10.5.1
Crane Suitability .................................................................................. 50
10.5.2
Work Baskets ....................................................................................... 50
10.6
Environmental Conditions .......................................................................... 51
10.6.1
Weather ............................................................................................. 51
10.6.2
Visibility ............................................................................................. 51
10.6.3
Daylight ............................................................................................. 51
10.6.4
Rainfall & Electrical Storms .................................................................... 51
10.7
Communications ...................................................................................... 52
10.8
Crane ................................................................................................... 52
10.9
Personnel ............................................................................................... 52
10.9.1
Banksman .......................................................................................... 52
10.9.2
Personnel Working from the Work Basket .................................................. 52
10.10
Tool Bags .............................................................................................. 52
10.11
Safety.................................................................................................... 52
10.11.1
Toolbox Talk ........................................................................................ 52
10.11.2
Recovery Arrangements .......................................................................... 53
10.12 10.12.1 10.13
Maintenance ........................................................................................... 53 Planned maintenance ............................................................................. 53 Administrative and Operational Duties ......................................................... 53
10.13.1
Person in Charge .................................................................................. 53
10.13.2
Banksman ........................................................................................... 54
10.13.3
Crane Driver ....................................................................................... 54
10.13.4
Riggers............................................................................................... 54
10.13.5
Personnel Working from a Workbasket ...................................................... 55
10.13.6
Crane Owner’s Requirements................................................................... 55
10.13.7
General Precautions .............................................................................. 55
10.13.8
Carrier Pre-use Inspection Check ............................................................. 56
10.13.9
Trial Lifts ............................................................................................ 56
11.0
Use of Mobile Cranes on Marine Vessels ....................................................... 57
11.1
Purpose ................................................................................................. 57
11.2
Scope .................................................................................................... 57
11.3
Requirements .......................................................................................... 57
11.3.1
Crane Suitability .................................................................................. 57
11.3.2
Types of Mobile Cranes......................................................................... 58
11.3.3
Crane Capacity .................................................................................... 59
Page 6 of 247
11.3.4 11.4 11.4.1 11.5
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Crane Stability for Deck Mounted Cranes .................................................. 59 Weather Criteria and Mobile Offshore Unit (MOU) Stability .............................. 60 Weather Criteria And Mobile Offshore Unit Stability ................................... 60 Mobile Cranes Tied-Down, Free Lifting and Travelling With Load ....................... 60
11.5.1
Vessel deck Strength ............................................................................ 60
11.5.2
Mobile cranes tied-down ....................................................................... 60
11.5.3
Mobile cranes free lifting ...................................................................... 61
11.5.4
Mobile cranes travelling with load .......................................................... 61
11.5.5
Mobile cranes used for basket transfer ...................................................... 62
11.5.6
Procedures .......................................................................................... 62
11.6
Documentation ........................................................................................ 62
11.7
Periodic Checks ....................................................................................... 62
11.7.1
General ............................................................................................. 62
11.7.2
Crane Pre-start Checks ......................................................................... 62
11.7.3
Reporting of defects and incidents........................................................... 63
11.8
Maintenance ........................................................................................... 63
11.8.1
General ............................................................................................. 63
11.8.2
Planned maintenance ............................................................................ 63
12
Fork Lift Trucks ........................................................................................ 64
12.1
General ................................................................................................. 64
12.2
Pre-Use .................................................................................................. 64
12.2.1
Start vehicle inspection .......................................................................... 64
12.2.2
Ignition ON checks .............................................................................. 64
12.2.3
Engine Running Checks ......................................................................... 65
12.2.4
Pre-use checks for forklift trucks not in use for an extended period of time ....... 65
12.2.5
Documents ......................................................................................... 66
12.2.6
Hazardous Zone Requirements ................................................................. 66
12.3
Operations ............................................................................................. 66
12.4
Capacity ................................................................................................ 66
13
Mechanical Handling Equipment .................................................................. 67
13.1
General Requirements ............................................................................... 67
13.2
Aerial Platforms....................................................................................... 67
13.3
Design Criteria - General .......................................................................... 67
13.3.1
Identification of Mobile Aerial Platforms .................................................. 67
13.3.2
Pre-Use Operational Checks ................................................................... 67
13.3.3
Operational Use. ................................................................................. 68
13.4 13.4.1 14.0
Hand trucks ............................................................................................ 70 General Requirements ........................................................................... 70 Crane Operation ...................................................................................... 71
Page 7 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
14.1
Introduction ............................................................................................ 71
14.2
Regulations and Documents for safe Offshore Crane Operations ........................ 71
14.3
Lifting Team ............................................................................................ 71
14.4
Crane Operator ....................................................................................... 71
14.4.1
Crane Operator’s Responsibilities ........................................................... 72
14.5
Rigger/Slinger ........................................................................................ 72
14.6
Banksman ............................................................................................... 72
14.7
Banksman/Slinger Activities ....................................................................... 72
14.8
Load Charts ............................................................................................ 75
14.9
Protocol for the use of two-way radio communications ..................................... 76
14.10
Two-way Radio Communications - General Information .................................... 76
14.10.1 14.11
Banksman - Radio Communication ............................................................ 77 Pre-Use Crane Inspection ........................................................................... 77
14.11.1
Pre-requisites....................................................................................... 77
14.11.2
Crane Access ....................................................................................... 78
14.11.3
Housekeeping ...................................................................................... 78
14.11.4
Safety Equipment .................................................................................. 78
14.11.5
Crane Pre-start Checks .......................................................................... 78
14.11.6
Pre-use checks for cranes not in use for an extended period of time ................ 79
14.11.7
Crane Refuelling ................................................................................... 79
14.11.8
Crane Start-up ..................................................................................... 80
14.12
Crane Function Tests ................................................................................. 80
14.12.1
Function Test Crane Controls ................................................................... 80
14.12.2
Function Test Limit Switch Cut-outs ........................................................... 80
14.12.3
Rated Capacity Indicators RCI (Automatic Safe Load Indicators - ASLI) ............ 81
14.12.4
Emergency Load Release System............................................................... 81
14.12.5
Emergency Stop Buttons ......................................................................... 82
14.12.6
System Checks Whilst Crane is Running ..................................................... 82
14.13 14.13.1 14.14
Routine Crane Operations .......................................................................... 82 Signalling ........................................................................................... 82 Load Handling on the Platform Deck............................................................. 83
14.14.1
Routine Lifts ........................................................................................ 83
14.14.2
Non-routine Lifts ................................................................................. 83
14.14.3
Platform Deck Work .............................................................................. 83
14.15
Cargo handling - supply vessel work ............................................................ 85
14.15.1
Routine Lifts ........................................................................................ 85
14.15.2
Non-routine Lifts .................................................................................. 85
14.15.3
Vessel Cargo Handling Operations ........................................................... 85
14.16
Transport of scaffolding Materials and Boards ............................................... 86
Page 8 of 247
14.17
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
General Operating Instructions ................................................................... 87
14.17.1
Stabilise the Lift ................................................................................... 88
14.17.2
Trial Lifting ......................................................................................... 88
15.0
Sub-sea Lifting and hoisting operations ........................................................ 89
15.1
Competence ............................................................................................ 89
15.2
Categorisation of Lifts ............................................................................... 89
15.3
Lift Planning ........................................................................................... 89
15.4
Management of Change ............................................................................. 89
15.5
Sub-sea lifting rules & sub-sea clarifications ................................................. 89
15.6
Load Handling ......................................................................................... 90
15.7
Competence of Personnel ........................................................................... 90
15.8
Load Charts ............................................................................................ 90
15.9
Crane Maintenance .................................................................................. 90
15.10
Rope Maintenance .................................................................................... 91
15.11
Crane Inspection ...................................................................................... 91
15.12
Rope Inspection ....................................................................................... 91
15.13
Crane/Rope Records ................................................................................. 92
16
Mobile Crane Operations .......................................................................... 93
16.1
Documents .............................................................................................. 93
16.2
Load Charts ............................................................................................ 93
16.3
Sitting of Cranes ...................................................................................... 94
16.4
Preparation ............................................................................................ 95
16.5
Lift Plans ................................................................................................ 96
16.6
Environmental Conditions .......................................................................... 96
16.7
General Operating Instructions ................................................................... 97
17.0
Multiple Crane Lifts .................................................................................. 98
17.1
Safety Measures for Multiple Crane Lifts ....................................................... 98
17.2
Calculated Share of the Load ...................................................................... 98
17.3
Principles for Multiple Crane Lifting ............................................................. 98
17.4
Mass of the Load ..................................................................................... 99
17.5
Position of the Centre of Gravity ................................................................. 99
17.6
Mass of the Lifting Gear ............................................................................ 99
17.7
Safe Working Capacity of the Lifting Gear .................................................... 99
17.8
Synchronisation of Crane Motions ............................................................... 99
18.0
Precautions when Using Mobile Cranes ....................................................... 100
18.1
Lattice Boom Cranes ............................................................................... 100
18.2
Hydraulic Boom Cranes ........................................................................... 100
18.3
Precautions with Pick-and-Carry Cranes...................................................... 100
19.0
Vehicle-Loading Cranes ........................................................................... 101
Page 9 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
19.1
General use .......................................................................................... 101
19.2
Crane and Vehicle Suitability ................................................................... 101
19.3
Rated Capacity Limiters ........................................................................... 101
19.4
Operational Issues for Vehicle-Loading Cranes ............................................. 101
20.0
Use of Tag Lines .................................................................................... 103
20.1
Risks ................................................................................................... 103
20.2
Make-up of Lines ................................................................................... 103
20.3
In Use.................................................................................................. 103
21.0 21.1
Sling Wire Diameters and Master links ....................................................... 105 Multi-leg Slings .................................................................................... 105
22.0
Pallets ................................................................................................. 106
23.0
Pre & Post-Use Checks and Safe Use of Lifting Appliances and Lifting Tackle ...... 107
23.1
Introduction ......................................................................................... 107
23.2
Lifting Appliances and Lifting Tackle ......................................................... 107
23.3
Identification and Certification ................................................................ 107
24.0
Control Of Portable Lifting Appliances and Lifting Tackle ............................... 108
24.1
Equipment Standards .............................................................................. 108
24.2
Storage............................................................................................... 108
24.3
Certification/Change out ........................................................................ 108
24.4
Equipment Marking and Tracking ............................................................. 108
24.5
Contents Register and Other Documentation................................................ 109
24.6
Rigging Store Control ............................................................................ 109
24.7
Colour Coding ...................................................................................... 109
24.8
Cleaning of Equipment ........................................................................... 109
24.9
Maintenance and Inspection .................................................................... 110
24.10
Damaged Lifting Equipment ..................................................................... 110
24.11
Retirement of Lifting Equipment ................................................................ 110
24.12
Contractors Using Their Own Lifting Equipment On SMEP Platforms/Worksites .... 110
24.12.1
Equipment Marking/Tracking ............................................................... 110
24.12.2
Equipment Register and Other Documentation ........................................... 110
24.13 25.0
Pre-Use Inspection - Basic Requirements .................................................... 111 Pre-use checks for lifting appliances not in use for an extended period of time ... 112
25.1
Equipment Identification Markings ............................................................ 112
25.2
Identification Number/Mark .................................................................... 112
25.3
Colour Coding System ............................................................................ 112
25.4
Documentation Accompanying Lifting Equipment .......................................... 113
26.0
Wire Rope and Wire Rope Slings .............................................................. 114
26.1
Wire Rope ........................................................................................... 114
26.2
Types of Lay ........................................................................................ 114
Page 10 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
26.3
Wire Rope Slings .................................................................................. 115
26.4
Sling Identification ................................................................................ 115
26.5
Pre-use ............................................................................................... 117
26.6
Safe Use .............................................................................................. 117
27.0
Wire Clamp (ASBRO) Pre-Use Inspection ..................................................... 122
27.1
Rejection ............................................................................................. 122
27.2
Care and maintenance ........................................................................... 122
27.3
After Use ............................................................................................ 122
28.0
Chain Slings and Fittings ......................................................................... 123
28.1
Barrel Slings ......................................................................................... 123
28.2
Pre-use ............................................................................................... 124
28.3
Safe Use ............................................................................................. 124
28.4
After Use ............................................................................................ 125
28.5
Barrel Lifters ........................................................................................ 125
29.0
Man-Made Fibre (Webbing) Slings............................................................. 127
29.1
Webbing (Round and Flat) Sling WLL Colour Coding .................................... 128
29.2
Pre-use ............................................................................................... 129
29.3
Safe Use ............................................................................................. 129
29.4
Prohibited Lifts ..................................................................................... 129
29.5
Special Applications .............................................................................. 130
29.6
After Use ............................................................................................. 130
30.0
Hooks .................................................................................................. 132
30.1
Pre-use ............................................................................................... 133
30.2
Scissor Hook Inspection ........................................................................... 134
30.3
Safe Use .............................................................................................. 134
30.4
After Use ............................................................................................ 135
31.0
Shackles .............................................................................................. 136
31.1
Pre-use Inspection ................................................................................. 136
31.2
Safe Use .............................................................................................. 137
31.3
After Use ............................................................................................ 139
32.0
Eyebolts ............................................................................................... 140
32.1
Eyebolt with Link.................................................................................... 140
32.2
Collar Eyebolt ....................................................................................... 140
32.3
Pre-use Inspection .................................................................................. 141
32.4
Safe Use .............................................................................................. 142
32.5
After Use ............................................................................................. 144
32.6
Swivel Hoist Rings .................................................................................. 144
32.7
Pre-use ............................................................................................... 145
32.8
Safe Use ............................................................................................. 145
Page 11 of 247
32.9 33.0
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
After Use ............................................................................................ 145 Beam Clamps ........................................................................................ 146
33.1
Universal Superclamps ............................................................................ 146
33.2
Pre-use Inspection ................................................................................. 147
33.3
Beam Clamp Safe Use ............................................................................ 147
33.4
After Use ............................................................................................. 148
34.0
Beam Trolleys ........................................................................................ 149
34.1
Push Type Trolleys ................................................................................. 149
34.2
Gear Type Trolleys ................................................................................ 149
34.3
Beam Trolley Installation ........................................................................ 149
34.4
Anti-tilt Device ..................................................................................... 150
34.5
Pre-use Inspection ................................................................................. 150
34.6
Safe Use ............................................................................................. 151
34.7
After Use ............................................................................................ 151
35.0
Plate Clamps ......................................................................................... 152
35.1
Pre-use ............................................................................................... 153
35.2
Horizontal Plate Clamps ......................................................................... 153
35.3
Universal (Vertical) Plate Clamps ............................................................ 154
35.4
Safe Use of Plate Clamps ........................................................................ 155
36.0
Rigging Screws / Turnbuckles ................................................................... 157
36.1
Pre-use ................................................................................................ 157
36.2
Safe Use ............................................................................................. 158
37.0
Wedge and Socket ................................................................................. 160
37.1
Pre-use ............................................................................................... 161
37.2
Safe Use ............................................................................................. 162
38.0
Lifting Nipples and Lifting Caps ................................................................ 163
38.1
Pre-Use ............................................................................................... 163
38.2
Safe Use ............................................................................................. 163
39.0
Runway Beams....................................................................................... 164
39.1
Beam Identity ....................................................................................... 164
39.2
Uncertified Lifting Beams ........................................................................ 165
39.3
Pre-use Inspection ................................................................................. 165
39.4
Safe Use ............................................................................................. 166
40.0
Lifting Points ......................................................................................... 167
40.1
Padeyes .............................................................................................. 167
40.2
Bolt-on Pad Eyes ................................................................................... 168
40.3
Pre-use Inspection ................................................................................. 168
40.4
Safe Use ............................................................................................. 168
40.5
Other Types of Lifting Points ................................................................... 169
Page 12 of 247
40.6
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Additional Lifting Points ......................................................................... 169
41.0
Spreader Beams and Lifting Frames ........................................................... 171
42.0
Manually-Operated Hoists ....................................................................... 172
42.1
Ratchet Lever Blocks (Pull Lifts or Chain Lever Hoist)..................................... 172
42.2
Pre-use ............................................................................................... 173
42.3
Safe Use ............................................................................................. 174
42.4
After Use ............................................................................................. 177
42.5
Ratchet Lever Blocks in an Offshore Sub-Sea Environment .............................. 177
42.6
Hand-Operated Chain Blocks ................................................................... 178
42.7
Chain Block Usage Terminology ............................................................... 179
42.8
Various Types of Chain Block .................................................................. 179
42.9
Chain Block Safety Considerations ............................................................ 179
42.10
Pre-use ............................................................................................... 180
42.11
Safe Use ............................................................................................. 181
42.12
After Use ............................................................................................ 183
42.13
Manual Chain Blocks in an Offshore Sub-Sea Environment ............................. 184
43.0
Powered Chain Hoists ............................................................................. 185
43.1
Pneumatic Chain Hoists .......................................................................... 185
43.2
Electrically Powered Chain Hoists ............................................................. 185
43.3
Pre-use ............................................................................................... 186
43.4
Safe Use ............................................................................................. 187
44.0
Lifting and Pulling (Tirfor) Machines .......................................................... 188
44.1
Tirfor Use - Safety Considerations ............................................................ 188
44.2
Pre-use ............................................................................................... 188
44.3
Inserting the Maxiflex Load Rope into the Tirfor Machine .............................. 190
44.4
Safe Use ............................................................................................. 190
44.5
After Use ............................................................................................ 191
45.0
Snatch Blocks ........................................................................................ 192
45.1
Wire rope Pulley Blocks.......................................................................... 192
45.2
Pre-use ............................................................................................... 192
45.3
Safe Use ............................................................................................. 193
45.4
After Use ............................................................................................ 194
46.0
Winches ............................................................................................... 195
46.1
Man-riding Winches .............................................................................. 196
46.2
Hand-Operated Winches ......................................................................... 197
46.2.1
Pre-use ............................................................................................. 197
46.3
Safe Use ............................................................................................. 198
46.3
Electric or Air Driven Winches .................................................................. 198
46.3.1
Pre-use ............................................................................................. 198
Page 13 of 247
46.4 47.0
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Safe Use ............................................................................................. 199 Hydraulic Jacks, Rams and Pumps.............................................................. 200
47.1
Pre-use ............................................................................................... 201
47.2
Ratchet Jacks ....................................................................................... 201
47.3
Hydraulic Jacks .................................................................................... 201
47.4
Safe Use ............................................................................................. 202
47.5
After Use ............................................................................................ 202
48.0
Overheard Cranes .................................................................................. 203
48.1
Hoisting and Travelling Units................................................................... 203
48.2
Pre Use ............................................................................................... 204
48.3
Safe Use ............................................................................................. 205
48.3.1 49.0
Do Not: ............................................................................................ 206 Vehicle Loading Cranes (e.g. Hiab Crane) ................................................... 207
49.1
Pre Use ............................................................................................... 207
49.2
Safe Use ............................................................................................. 207
50.0
Flexible Intermediate Bulk Containers (FIBC) ................................................ 208
50.1
Lifting of filled FIBCs ............................................................................. 208
50.2
Pre-Use ............................................................................................... 208
50.3
Repair of FIBCs .................................................................................... 208
50.4
How to use FIBCs .................................................................................. 208
50.5
Lifting FIBCs ........................................................................................ 209
50.6
Lifting with Cranes ................................................................................ 210
50.7
Carrying With Fork Lift Trucks ................................................................. 210
51.0
Containers ............................................................................................ 212
51.1
Wire rope slings ................................................................................... 212
51.2
ISO Containers ..................................................................................... 213
52.0 52.1
Pennants/Stingers .................................................................................. 214 Pennant Assembly ................................................................................. 214
Appendix 1
Crane Banksman Hand Signals ............................................................ 215
Appendix 2
Flow Chart Lifting and Hoisting Operations ........................................... 219
Appendix 3
Mobile Crane Lift Planning Sheet ......................................................... 221
Appendix 4
Appliance Lift Planning Sheet ............................................................. 223
Appendix 5
Carrier Transfer Checklist .................................................................. 225
Appendix 6
Carrier Transfer Passenger Checklist .................................................... 226
Appendix 7
Personnel Transfer Request ................................................................ 227
Appendix 8
Installation Of Wire Rope Double Saddle Grips ...................................... 228
Appendix 9
Shackle – Split Pin Sizes .................................................................... 230
Appendix 10
Overload Protection and Anti-Two-Block Requirements ............................ 231
Appendix 11
Glossary of Terms ........................................................................... 232
Page 14 of 247
1.0
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
PREFACE.
When items are lifted it is often the case that the first available piece of lifting equipment is used. Conveniently available lifting appliances and lifting tackle are randomly requisitioned and the lift undertaken and often with disastrous consequences. The “can do” attitude often contributes to the eventual accident. Although the above bad practice cannot be identified to a specific area of the oil and gas exploration and production industry, the dangers of the “can do” attitude must be understood if accidents are to be avoided. No job is so important that cannot be carried out safely.
The author and review team members would like readers to note that, whilst every practical attempt was made to ensure the accuracy and scope of the content of this document, due to the size of the task and the given timescale, there may be some unintentional errors or omissions. Comments (recommendations, additions or deletions) and any pertinent data that may be of use in improving this document are encouraged and should be addressed to the author for consideration for inclusion in the next revision. Users are cautioned that adherence to this Manual alone does not exclude the use of competent engineering judgment.
1 .1
P o s si b l e R e a s o n s F o r A c ci d en t s
Possible contributory reasons for accidents occurring during lifting operations are briefly listed below.
1 .1 .1
C o n tri but ory F a ct or s
•
Inadequate planning of the lifting operation.
•
Inadequate pre-operation risk assessment.
•
Inadequate control of operations
•
Inadequate operator training standards.
•
Inadequate continuous assessment systems.
•
Acceptance of the “can do” culture.
1 .1 .2
Op era t or Er r or
Operator errors such as “overloading”, incorrect selection of equipment, incorrect attachment of equipment, inability to recognize faulty equipment etc. can often be attributed to: •
Incorrect level of “Competency”.
•
Inadequate training.
•
Inadequate job information
•
Not recognizing the hazards involved.
1 .1 .3
Eq uipm ent Fa il ure
Equipment failure is often due to: •
Inadequate storage facilities.
Page 15 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
•
Inadequate routine maintenance management.
•
Lack of examination and certification
•
Lack of written routine maintenance instructions.
•
Misuse.
In order to avoid lifting incidents, the introduction and implementation of a “Safe System of Work” is essential. Before any lifting operation takes place a briefing (toolbox talk) must be given to all personnel involved in order that the requirements of the lift are fully understood.
1 .1 .4
Saf e Sy st em of W ork
A safe system of work is a step-by-step description of any task or process that takes into account the hazards likely to be encountered. The following summarises the requirements of a safe system of work:
•
Define the task.
•
Assess the risks.
•
Describe safe methods by writing /checking of lifting plan.
•
Measure and monitor its effectiveness.
The safe system of work procedures must also address the effective isolation of supplies and systems from the work area and stipulate what effective barriers must be in place to distance personnel working in the area from any hazard or danger. It is essential that the safe system of work lists all safety precautions that must be taken at each stage of the work.
1 .1 .5
R equir e ment s of a Sa fe System of W or k.
The following gives a brief summary of the subjects that must be considered before any lifting operation is started.
Pre assessment: Assess the hazards and associated risks. Assess the complexity of the work. Job Planning: Plan the work with respect to all personnel that are directly or indirectly involved. For example: •
Removal of an item of equipment from an enclosed bay on a platform may involve moving other personnel from the work area, closing access routes and/or removal of structures to establish a removal route.
•
How inherently dangerous is the task? What could go wrong? What could happen if the task is incorrectly performed?
•
Break down each individual’s task into steps or component activities and examine each step to see what could go wrong.
Equipment provision: Check availability of lifting appliances, lifting tackle and quantities required for every phase of the operation. Lifting appliances and tackle must be “certified” and
Page 16 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
comply fully with SMEP requirements. All equipment used during the lifting operation must undergo pre-use, pre-start and function checks. Work Area: Work areas will have differing constraints; the area may have restricted machinery space, or one where the lift is being carried out on an open deck. Each must be considered on it’s own individual merits. Environment: Environmental
considerations shall
include external weather conditions and
internal constraints such as confined spaces e.g. Ensure that the area is gas free before entry and arrange for continuous monitoring during work period. Personnel: Numbers must be adequate to safely carry out the task. Anticipate the possible need for assistance, shift changes, back up etc. Is additional Personnel Protective Equipment (PPE) required? Communication: Establish a clear and effective system of communication between all personnel involved in the lifting operation. Person In Charge (PIC): Organise the person in charge for the task and personnel involved. Emergencies: Anticipate emergency requirements. Handover Log: Initiate a shift change handover log, which must be maintained so that it correctly informs the incoming shift of the current status of the lifting operation. Reporting System: Report all incidents that occurred during the operation and provide a meaningful summary using the Fountain reporting system.
Page 17 of 247
2.0
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Purpose
The purpose of this document is to describe how lifting equipment and activities, operated within SMEP onshore and offshore facilities and at any worksite where SMEP has a prevailing influence, are identified and that hazards associated with these activities are correctly identified, assessed and kept as low as reasonably possible (ALARP).
2 .1
S c op e
This standard applies to all SMEP and Contractors at all locations where SMEP has the prevailing influence. It covers lifting operations in connection with all the lifting equipment listed in Table 1 below.
Lifting Equipment
Lifting Appliance
Lifting Tackle
Cranes (Including): Offshore pedestal Mobile cranes A-Frames and derricks – not drilling (onshore and on barges) Tower cranes Overhead/gantry cranes Lorry loading cranes (HIAB’s) Runway beams/monorails Jacks Mobile Aerial Platforms Hoists • Manual lever • Tirfor/comealong •Powered overhead •Chain hoist •Chain block Padeyes (fixed structural) Winches (incl.Man-riding) Forklift trucks Beam clamps Beam trolley Sheave blocks
Wire rope slings Chain and chain slings Man made fibre slings Shackles Plate clamps Eye bolts and swivel Rings
Table 1.
Page 18 of 247
Lifted Equipment
Offshore containers Skips Skids Spreader beams Drum cages Gas cylinder racks Frames Cargo netting Baskets Pipe racks FIBC’’s (Big Bags) Pallets
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3.0
Certification
3 .1
I nt r odu c ti on
All lifting equipment used on SMEP onshore or offshore facilities by SMEP personnel, contractors or sub-contractors shall be accompanied by a current valid certificate of examination. RD
NOTE. CERTIFICATES OF EXAMINATION MUST BE ISSUED BY A SMEP RECOGNISED 3 PARTY LIFTING CERTIFICATION AUTHORITY.
3 .2
C er ti fi cat i on W i t h New Lift in g Eq uip men t
3 .2 .1
I nsp ec ti on C er tifi cat e
A declaration by the manufacturer that the products supplied meet the requirements of the order and which supplies specific test results. The Inspection certificate shall meet the requirements of ISO 10474 type 3.1B or BS EN 10204:2004. Inspection Certificates for any item of lifting equipment shall be kept by the owner/user in a safe place and be readily accessible for as long as the equipment is in use. The Inspection Certificate shall accompany lifting equipment being transferred for use in a different location.
3 .2 .2
Op era ti ng and Ma in tena nce I n stru c ti on s
It is a requirement that written Operating and Maintenance Instructions must accompany all new equipment. These instructions (or photocopies) must be kept in a place of safety, with the equipment, and be readily available to the end user.
They are normally stored at the location where the lifting equipment is being used. However, where this is not possible e.g. due to space constraints, they may be stored elsewhere provided that they are readily accessible.
3 .3
C er ti fi cat i on of E xi sti ng Lif ti ng Equ i pme nt
All lifting equipment on SMEP facilities, and those owned by contractors or sub-contactors used on SMEP onshore or offshore facilitates or where SMEP has the prevailing influence, shall be accompanied by a current valid certificate of examination issued from a SMEP recognised third party certification company.
3 .4
R ete nti on Peri od f or Ce rti fi ca te s a nd Rep or ts.
3 .4 .1
I nsp ec ti on C er tifi cat e s
Inspection Certificates are valid for the lifespan of the lifting equipment.
Page 19 of 247
3 .4 .2
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
T hor o ug h Ex ami nati on C e rti f i ca tes
The owner of lifting equipment is responsible for ensuring that all lifting equipment is examined and certified in accordance with IMP 0.03 Lifting Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032). Thorough Examination Certificates/ Reports are a record of the physical condition of lifting equipment at that moment in time and any testing that was carried out. When statutory testing is carried out and the results recorded, a date for retesting will be specified and such Certificates and Reports are considered to have finite validity.
The retention period for certificates and reports are listed in EPA Document Management Code of Practice EPA 20040901 0001.
Page 20 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
4.0
Maintenance of Lifting Equipment
4 .1
I nt r odu c ti on
All lifting equipment on SMEP facilities, and those owned by contractors or sub-contactors used on SMEP onshore or offshore facilitates or where SMEP has the prevailing influence shall have a preventive maintenance routine and shall be maintained by personnel qualified to undertake this work.
All SMEP items of lifting equipment, with the exception of loose lifting tackle, shall be registered in SAP. The maintenance, examination and overhaul intervals shall be as per Appendix 1 of IMP 0.03 Lifting Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032) or the manufactures maintenance instructions. Contractors shall maintain a register of all their owned lifting equipment.
Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-ST (section 4.10 page 13) The maintenance history of all items of lifting equipment shall be fully captured in SAP. Contractors shall maintain maintenance history of all their owned lifting equipment.
Page 21 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
5.0
Marking of Lifting Equipment
5 .1
R equir e ment s
It is the requirement of SMEP to have all lifting equipment clearly marked to indicate their working load limit or safe working load. 1.
Where the working load limit or safe working load of the equipment depends on its configuration, the equipment shall be clearly marked to indicate its working load limit or safe working load for each configuration.
2.
Lifting tackle shall be marked in such a way that it is possible to identify the characteristics necessary for their safe use.
3.
Lifting equipment, which is designed for lifting persons, is appropriately and clearly marked to this effect.
5 .2
W or ki n g L oa d Lim i t ( W L L) / Sa f e W or k i n g L oa d ( S W L)
5 .2 .1
Saf e W orkin g L oa d ( SW L) Ma rk
The SWL marking indicates the maximum load that the equipment may safely lift as certified by the competent person. Wherever possible, the actual value of the SWL must be marked (stamped) on the equipment in such a way that it cannot be easily removed. Where this is not practicable a system may be used to provide the user with the SWL e.g. attaching some label or tag (as happens with manmade fibre slings. The Safe Working Load (SWL) is a method of stating the maximum load or mass that an item of lifting equipment may raise, lower, or suspend.
5 .2 .2
W or ki ng L oad Lim it ( W L L) Mark
The Working Load Limit (WLL) is an internationally used term (meaning the same as SWL). The WLL marking indicates the maximum load that the equipment is designed to safely lift; the manufacturer normally marks it on the equipment. Sometimes it is referred to as the equipment’s “rated capacity”.
5 .2 .3
V a r i a b l e WL L or S W L
Where lifting machinery has a WLL or SWL which varies with it’s operating radius or is dependant upon how it is configured, it must be either clearly marked or have adequate information to indicate to the user it’s WLL or SWL at any particular configuration. These markings can be in the form of an indicator, plate or chart, which is normally visible/available to the operator during lifting operations. Where there is a significant hazard arising from the use of the machinery it must have appropriate equipment or devices such as rated capacity indicators and rated capacity limiters. Rated Capacity Indicators (RCI) were previously known as Automatic Safe Load Indicators (ASLI’s) or Safe Load Indicators (SLI’s) or moment load indicators.
Page 22 of 247
5 .2 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
D e -rat i ng
If it is not possible to provide a value for the SWL for all configurations, the capacity of the equipment must be reduced (de-rated) to allow for all configurations for a factor of safety. When necessary, this form of de-rating must only be carried out by a competent person in consultation with the equipment manufacturer and reviewed by the Lifting Technical Authority.
5 .2.5
Li fti ng Eq ui pme nt a ssemb ly
Where a number of pieces of lifting tackle are assembled to form one lifting assembly, which is not dismantled after use, the assembly must be permanently marked to indicate it’s assembled Working Load Limit (WLL). i.e. Multi-leg slings are marked with its WLL and the angle (from the vertical) at which the WLL applies, e.g. SWL x Tonne 0° to 45° from the vertical.
5 .2 .6
Li f ti ng A c ces s o ry C onfigur ati on s
If the configuration of an accessory can effect the WLL or SWL, e.g. multi-legged sling, it must be clearly and permanently marked to provide the user with information on the SWL for each configuration e.g. 6.9 tonne @ 0 to 45 degrees from the vertical.
5 .2.7
A cce s s o r i e s- O t h e r F a c t or s
If a lifting accessory, such as a plate clamp, can be adversely affected by other factors, this must be clearly marked with the plate thickness range of plates over which it can be safely used.
5 .2 .8
Li f ti ng Eq ui pme nt f or Lif t i ng Per son s
Lifting equipment, which is designed for lifting persons, must be clearly and permanently marked that it is for lifting persons. In addition, the carrier (e.g. a suspended personnel basket) must clearly display the maximum number of persons to be carried. The SWL must also be clearly and permanently marked on the carrier. For details of equipment used for personnel lifting see Section 9. Lifting equipment, which may be inadvertently used for lifting people, but was not designed for that purpose, shall be clearly and permanently marked that it is not to be used for lifting people.
5 .2 .9
G an gw ay s
All platform gangway lifting/rigging equipment shall be clearly tagged indicating the safe working load maximum rigging angle from the vertical when in service.
5 .2 .1 0
Eq uipm ent Id e ntit y Marki ng
All items of lifting equipment shall have a permanent unique identification number marked on, or attached to it, through which it can be identified throughout its lifespan.
Page 23 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
6.0
Lifting Equipment Colour Codes
6 .1
Li fti ng Eq ui pme nt Col our Codi ng S y stem
All lifting tackle owned by SMEP or used on SMEP offshore or onshore facilities must undergo a thorough inspection every 6 months. The colour coding system used by SMEP, is detailed in IMP0.03 Lifting Equipment )SMEP.EP72.ST.0032), is to indicate to end users that the lifting tackle has passed the 6 monthly thorough inspection and is suitable for use. The colour code is valid for a set period of 6 months and only lifting tackle displaying this colour code may be used. The colour code, which is currently valid, shall be displayed at all SMEP locations where lifting and hoisting activities are carried out.
Page 24 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
7.0
Training of Personnel
7 .1
T ra inin g Res p on sib il i tie s
All SMEP and Contractor personnel engaged in lifting and hoisting operations shall meet the Competence Standards set out in Appendix 1 of Lifting Equipment Management System EP200803208668. W h e r e d e f i c i e n c i e s a r e f o u n d t h e y s h a l l b e a d d r e s s e d b y t r a i n i n g . T h e t r a i n i n g must provide levels of competence that will eliminate incorrect operations/activities and minimize the potential for human error that might otherwise contribute to an incident.
7 .2
T ra inin g
Personnel who must be adequately trained are listed in Appendix 1 of Lifting Equipment M a n a g e m e n t S y s t e m EP200803208668. T h e t r a i n i n g s h a l l b e u n d e r t a k e n a t a S M E P a p p r o v e d training provider.
7 .2 .1
Addi ti onal T ra inin g
Additional training will be necessary when: •
The risks to which personnel are exposed to change due to a change in work tasks.
•
New equipment is introduced.
•
The system of work changes.
7 .2 .2
T ra inin g f or New and I ne xp eri en ced P erso n ne l
Training and supervision of new personnel is particularly important because of their unfamiliarity with the working environment. Safety induction and familiarisation training shall be carried out.
7 .2 .3
P er son ne l U nder Tr aini ng
Personnel under training must only undertake tasks appropriate to their assessed level of competence.
7 .2 .4
Q ua li f i ca tio n Up da te s
Some qualifications are valid for a set period of time after which they expire and requalification is required. A system must be in place to keep track of this and ensure a timely re-qualification.
Page 25 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
8.0
Planning, Definitions and Execution of Lifts
8 .1
P urp o se
The key to safe lifting operations in SMEP is having competent personnel using the correct equipment in a planned safe manner. This section outlines the issues relating to the selection of the correct people, i.e. crane operator, banksman, rigger etc. for the task. It describes operational practices to be used by these people as part of a planned safe and effective crane and rigging programme. Attention is drawn to the relevant sections of the Shell global standard on lifting and hoisting EP2005-0264-SP-01 (Section 4.2.2) and EP2005-0264-GL-01.
8 .2
S c op e
This section applies for all lifts using lifting appliances and accessories.
8 .3
R e sp onsi bi liti e s
The responsibilities of SMEP’s activity managers, supervisors, CSR’s OIM’s etc. and personnel involved in lifting operations can be found in Section 2.3 of Lifting Equipment Management S y s t e m , EP200803208668.
8 .4
Corr ect U se
The equipment shall be used only for the specific purpose for which it was designed and not be adapted for any other purpose without the approval of the Lifting Technical Authority.
8 .5
Safe t y Margi n
All lifting equipment and appliances used in the lifting process shall be rated at 30% or more above the maximum load to be lifted.
8 .6
Controlling Access t o the Lif t Area
Access to work areas and to the lifting equipment shall be properly controlled. This may include security measures and physical barriers. No person shall be allowed under a suspended load unless: •
There is clear justification and no suitable alternative was identified during planning
•
An independent second barrier is in place.
8 .7
R i s k A s se s sm e nt
8 .7 .1
Li f t P l an /J SA
Every lifting operation must have a lift plan and JSA
Page 26 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Every lifting operation shall be preceded by a Lift Plan and JSA to identify hazards, and ensure that safety barriers are in place to reduce the risk to As Low As Reasonably Practicable (ALARP). The Risk Assessment shall address, but is not limited to the following:
•
Classification of the lift.
•
Weight size, shape and centre of gravity
•
Availability of approved lifting points.
•
Methods of slinging, attaching and detaching the load.
•
Overturning, load integrity and the need for tag lines.
•
Suitability and condition of the lifting equipment to be used.
•
Initial and final load position, and how it will get there.
•
Lifting over live equipment.
•
Number and duration of lifts.
•
Conflicting tasks in the lifting area.
•
Environmental conditions, including weather and permissible limits.
•
Ground conditions and the expected ground loadings.
•
Lighting in the pick-up and lay down areas.
•
Proximity hazards, obstructions, path of load.
•
Working under suspended loads.
•
Access and emergency escape routes of the lifting equipment operator and load handlers.
•
Experience, competence and training of personnel
•
Number of people required for the task.
•
Step by step instructions.
•
Pre-use Inspection of equipment by the operator.
•
Visibility of the load by the operator and person guiding the load.
•
Method of communication between all personnel involvedin the operation and the , chain of command is clear.
•
Recovery and contingency plans.
Routine lifts are generally, but not always, considered with generic risk assessments.
8 .7 .2
R is k Mat ri x
The Risk Assessment Matrix (RAM), Appendix 1 EP 2005-0264-GO1, shall be used to determine the level of risk. If the risk is assessed as red, the task shall not proceed. The lift shall be re-assessed and further control measures put in place to reduce the risk.
Page 27 of 247
8 .7 .3 1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
10 Q ue sti on s F or a SA FE Lif t Are you aware of and fully conversant with the lifting and hoisting procedures applicable to the lift?
2.
Has everyone involved with this lifting operation attended the Toolbox Talk?
3.
Has a pre-use inspection of the lifting equipment been carried out and is the lifting tackle tagged or marked with: •
Safe working load.
•
A unique identification number.
•
A valid certification date.
4.
Are all the safety devices working?
5.
Do you know the Person-In-Charge of the lift?
6.
Is everyone competent and aware of his or her tasks?
7.
Is there a current Lift Plan and JSA, which manages risks?
8.
Do you know the environmental limits for the lift?
9.
Is the lift area controlled and is everyone clear if the load swings or falls?
10. Are signalling methods and communication agreed and clear to you?
8 .8
Li ft Ca teg or i sa ti on
Lifting operations shall be categorised to reflect increasing risk and consequent increasing level of control required. The categories of lifting operations are as follows:
8 .8 .1
R ou ti ne Lif t s
A generic risk assessment and lift plan must be used for routine lifts. However, classifying a lifting operation as “Routine” does not automatically make it a “Safe” lifting operation (most incidents associated with lifting occur during “Routine” operations). The risk assessments and lift plan shall always be reviewed during toolbox talks for continued applicability. If there are changes to the original plan a further risk assessment must be undertaken.
8 .8 .2
R ou ti ne Lif t
A Routine Lift is one where: 1.
Uncomplicated lifts that are performed on a regular basis or
2.
Which involve basic slinging practices or
3.
The gross load does not exceed 5 tonnes, and not exceeding 50% of the manufacturer’s capacity chart at the working radius.
4.
Only one lifting device is used for the lift.
Category of Lift
Control Measures
Competent Person
Lift Plan Reviewed by
Routine Crane Operations •
Within the normal
•
Risk Assessment
•
(generic)
Page 28 of 247
Crane Operator
•
Person in Charge (PIC)
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
operating parameters of
•
the crane. •
Lifting over a safe areas
•
Suitable environmental
•
•
•
Lift Plan
•
Banksman
(generic)
•
Deck Crew
Risk Assessment
•
Drilling crew
(generic)
•
Construction
Job Safety Analysis
conditions
•
Toolbox Talk
Familiar, competent
•
Safety checklist
crane operators
•
10 questions for
Load has known and
a safe lift
evaluated weight, shape and centre of gravity •
Standard rigging arrangements
Routine repetitive Lifting
•
Operations using the same Equipment (e.g. Drilling or
•
Construction Crews) •
Load has pre-determined
•
Single function or series of functions repeated
•
Order of function
•
Same equipment
•
Same operators
Routine Lifting Operations
Equipment used at the
Same equipment
•
Stable known
•
•
Job Safety
Toolbox Talk
•
Safety checklist
•
10 questions for a safe lift
•
Risk Assessment
•
Lift Plan
•
•
Job Safety Analysis
•
Toolbox Talk
Familiar, competent
•
Safety checklist
equipment operators
•
10 questions for a safe lift
evaluated weight, shape and centre of gravity •
Maintenance Technicians
(generic)
environment
Load has known and
•
(generic)
same location •
crew
Lift Plan
•
with Loose Lifting Equipment •
(PIC)
Analysis
repeated •
Person in Charge
(generic)
weight, shape and centre of gravity
•
Standard rigging arrangements
Page 29 of 247
Drilling Crew
•
Person in Charge (PIC)
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
8 .8 .3
N on -R o uti ne – SI M PLE
A Non-routine Simple Lift is one where: 1.
It is not Routine as defined in 8.8.2 above, or
2.
The gross load weight does not exceed 25 tonnes, and does not exceed 75% of the manufacturer’s capacity chart, and
3.
Lift is in non-sensitive or unrestricted areas, and Load is with required lifting points or easy to sling
4.
Only one lifting device is used for the lift.
Category of Lift
Control Measures
Competent Person
Lift Plan Reviewed by
Non-Routine – SIMPLE •
•
•
•
technicians •
Load has known and
(prepared by
Level 1 & 2
evaluated weight of < 25
competent
tonnes
rigger)
Centre of gravity is
•
Job Safety Analysis
Use of certified lifting
•
Toolbox Talk
point directly above the
•
Safety checklist
load
•
10 questions for
•
Ample headroom
•
Lifting in non-sensitive,
a safe lift
non-difficult or unrestricted area •
Single lifting appliance
•
Unlikely to be effected by changing environmental conditions
•
Experienced and competent operator
•
Standard rigging arrangements
•
Suitable lay down area available
•
Hoist suspended from a dedicated lifting structure or runway beam
•
Maintenance
Lift Plan
below sling attachments •
Risk Assessment (generic)
Equipment installed by competent operator
•
•
Lifts from one offshore vessel to another
Page 30 of 247
Banksman
•
Person in Charge (PIC)
8 .8 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
N on -R o uti ne – CO MP LIC A TE D
A Complicated lift is one where: 1.
The load is an awkward shape or offset or a high centre of gravity, or
2.
The load is fragile, contains liquid or is difficult to sling, or
3.
Two or more pieces of lifting equipment are required in unison i.e. tandem lifts, or
4.
Non-standard crane configurations are used, or
5.
The gross load is greater than 25 tonnes, or
6.
The gross load represents more than 75% of the manufacturer’s capacity chart at the working radius, or
7.
The gross load is greater than 25 tonnes and is also greater than 80% of the manufacturer’s capacity chart.
Category of Lift
Control Measures
Competent Person
Lift Plan Reviewed by
Non-Routine – COMPLICATED •
•
•
equipment (due to malfunction, inadequacy or unsuitability •
Use of two or more items of Lifting Equipment, including tailing pipe using winch and crane (tandem lifting)
•
Within sensitive, difficult
•
(Specific)
Continuation of a lifting operation with different
Risk Assessment
Lift Plan
Supervisor •
(specific) •
Permit to Work
•
Toolbox Talk
•
Job Safety Analysis
•
Safety checklist
•
10 questions for a safe lift
or restricted areas •
Load that requires to be rotated or across hauled involving two or more sets of rigging
•
Awkward shape, offset or high centre of gravity, fragile, containing liquids
•
No lifting attachments and difficult to sling
8 .8 .5
N on -R o uti ne – CO MP LEX
A complex lift is one where: 1.
Technical
Any of the above, but with additional hazards, or
Page 31 of 247
Lift planner
•
Lifting Technical Authority
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
2.
The load is lifted over, or near, operating equipment or electrical power lines, or
3.
Lifting of personnel, floating cranes, sub-sea lifts, or
4.
The gross load is greater than 75 tonnes, or
5.
The gross load represents more than 90% of the manufacturer’s capacity chart at the working radius, or
6.
The gross load is greater than 75 tonnes and is also greater than 80% of the manufacturer’s capacity chart.
Category of Lift
Control Measures
Competent Person
Lift Plan Reviewed by
•
•
•
Formal work
•
Lift planner
Continuation of a lifting
pack with method
•
Professional
operation with different
statement
Non-Routine - COMPLEX
•
HAZID
changeover
•
HAZOP
Structural
Lifting of personnel,
•
Dropped object
Engineer
Riding •
study •
Over or in sensitive areas e.g. active or energised hydrocarbon
•
from one lifting appliance to another •
In environmental conditions likely to effect equipment performance
•
Operator under training
•
Load with unknown or
Lift Plan prepared and reviewed by a Professional
equipment. Transferring the load
Risk assessment (specific)
containing process
•
•
engineer •
Lifting analysis per SES10.1
•
Work Permit
•
Toolbox Talk
•
10 questions for a safe lift
difficult to estimate weight and / or centre of gravity •
Load is special and / or expensive the loss of which would have serious impact on production operations
•
Non-standard rigging arrangements
•
Load lowered into or lifted from a confined space
Page 32 of 247
Senior
Lifting Technical Authority
Engineer
personnel e.g. shift
including drill floor Man-
•
and •
Structural TA1
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
•
Sub-sea lifting
•
Lifting involving floating cranes
Lifts involving floating cranes or Sub-sea lifting must be reviewed by the Structural TA1.
8 .8 .6
N on -R o uti ne – HEA V Y
A heavy lift is one where: •
The weight of the load is in excess of 90% of the rated capacity of the lifting appliance.
Category of Lift
Control Measures
Competent Person
Lift Plan Reviewed by
•
Weight of load in excess
•
Lift plan
of 90% the rated capacity
prepared/review
of the lifting appliance
ed by a qualified engineer •
Risk assessment
•
Job Safety
•
Crane Operator
•
Banksman
•
Rigger
•
Lifting Technical Authority
Analysis •
Work Permit
•
Safety checklist
•
Toolbox Talk
•
10 questions for a safe lift
8 .9
E xe c uti o n
8 .9 .1
P erm it s
Prior to commencing lifting operations it must be ascertained whether a permit to work (PTW), as detailed in Permit To Work System procedure DIN: TCP.XX.1009, is required.
8 .9 .2
Pr e- lift Meeti ng s ( T oolb o x Ta lk)
A Toolbox Talk shall be held immediately before any lift to ensure that all personnel involved in the lift fully understand the JSA and Lift Plan. The PIC shall verify that the answers to “10 questions for a safe lift “ are all addressed.
8 .9 .3
C o nd u cti ng t he Li f tin g Op erat i on
The PIC shall ensure that lifting operations are carried out in strict accordance with the approved Lift Plan. Any variation from the agreed Lifting Plan shall result in the job being stopped and reassessed to ensure continued safe operation.
Page 33 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
9.0
Personnel Lifting
9 .1
P urp o se
This section describes the requirements for the transfer of personnel by personnel carrier and working at elevated heights from suspended work baskets/boxes and is based on the guidance given in:
1.
LOLER 98, Regulation 5.
2.
BS 7121, Part 11
3.
ASME B30.23.
Personnel carrier transfers and work basket operations are to be used in exceptional circumstances only, where no alternative means of carrying out the transfer of personnel or operation is available. In the situation where the transfer of personnel between a construction/pipelaying barge that is equipped with a helideck and a fixed offshore structure that is also equipped with a helideck is required, the use of a helicopter is mandatory.
Attention is drawn to the relevant sections of the Shell global standard on lifting and hoisting EP2005-0264-GL-01 (Section 4.2.2) and EP2005-0264-ST.
SMEP’s preferred method for basket transfer is using the “FROG”. The FROG is a semi-enclosed basket. Personnel are seated in the centre facing outward while being secured by a four-point safety belt. It is Shell’s policy to transfer personnel by means of basket only in exceptional cases (no other alternatives). In case another method than the FROG is applied, it has to be “equivalent” in terms of risk to personnel. Another acceptable method for basket transfer is the ESVAGT-Rigid basket. This basket has optical similarities to the conventional “Billy Pugh” design. However, the ESVAGT-Rigid basket is, fully compliant with the British LOLER regulations and it requires a different procedure for personnel transfer as personnel stand during the transfer inside the basket.
Page 34 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
NOTE: THE “BILLY PUGH” PERSONNEL TRANSFER CARRIER, SHOWN BELOW, IS NOT APPROVED FOR USE IN SMEP FOR PERSONNEL (PASSENGER) TRANSFER.
9 .2
S c op e
The scope of this section covers SMEP requirements for transferring people by personnel carriers and operating suspended workbaskets.
It specifies the requirements and defined instances where transfer by personnel carrier is allowed.
This standard prohibits a person from riding or travelling on a load, lifting hook, sling, platform or other lifting medium of a crane except in a specifically designed personnel transfer carrier that is solely used for that purpose. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-SP-01
9 .3
A ut hori ty
All personnel carrier transfers shall only be carried out using the SMEP Permit to Work system. To support the issuance of the permit to work, the attached carrier transfer checklist shall be utilised for each individual transfer (Appendix 5). For guidance on how to complete the work permit refer to DIN: TCP.XX.1009“Permit to Work System”
9 .4
Pr er equi site s
If a personnel transfer operation is to be carried out the following must be produced before the operation can start: •
Permit to Work.
•
Risk Assessment.
•
Lift Plan. (Written step-by-step instructions)
•
Safety Check List.
Page 35 of 247
9 .5
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ob je ctive s
Carrier transfers are not the preferred method of moving personnel. However, it is recognised that there are situations where this method of transfer may be justified. All carrier transfers must be covered by an appropriate SMEP Permit to Work, Risk Assessment and Lift Plan, and be conducted in accordance with this section.
9 .6
Pr o ced ure s
The contractor shall provide a procedure for personnel lifting. The procedure shall be forwarded to SMEP’s Lifting Technical Authority for review.
9 .7
Defined Cases
Personnel transfer by personnel carrier shall only be allowed in the following defined cases: 1.
When locating a Jack Up to a platform prior to the establishment of a gangway.
2.
Between MOU and a securely moored cargo barge alongside e.g. Helideck lift.
3.
For the purpose of vessel inspection during MOU location moves.
4.
Upon the initial arrival and/or final departure of a tender assisted rig at/from an SMEP platform. Prior to/after establishment of access between the rig and platform using the rig’s personnel bridge.
5. 6.
In case of emergency. During the construction/installation of a new platform/jacket when the only access is by personnel carrier.
In any other cases, where carrier transfers are deemed to be necessary, prior approval shall be obtained from SMEP’s HSE department and Lifting Technical Authority.
NOTE: UNDER NO CIRCUMSTANCE SHALL THE “PERSONNEL CARRIER” BE USED AS A WORKBASKET.
9 .8
Eme r gen c y C o ndit i o n s
Personnel may be transferred under emergency conditions where the risk of not transferring is considered greater than the risk of transfer. While it can be foreseen that such circumstances may arise, it is not practicable to try and envisage all possible cases and list them. Weather and other limitations for weather conditions will be made by risk assessment on a case by case basis by those involved in the transfer, but shall not exceed those governing crane operations or the launch of fast rescue craft.
9 .9 1.
R i s k A s se s sm e nt All personnel carrier lifting operations must be subject to a risk assessment and a lift plan
2.
The risk assessment shall identify all reasonably foreseeable hazards and failure scenarios, including crane operators state of mind, so that in all operations of the transfer personnel are protected from being crushed, trapped, struck or fall from the carrier.
3.
A written lift plan must be completed for the operation.
Page 36 of 247
4.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Emergency procedures shall be established e.g. emergency lowering in the event of crane breakdown, sudden change in sea/weather conditions.
5.
Appropriate crane and carrier checks to be recorded on the plan.
6.
The Person In Charge (PIC) must carry out the checks and supervise the operation defined in the lift plan.
9 .10 1.
Ot he r C onsi der at i ons Immediately before the lift the crane operator must check that the prevailing weather conditions e.g. wind speed and sea state criteria listed in 9.12.
2.
Check that other criteria required for the operation are met e.g. passengers are wearing life jackets or an approved flotation work vest, and have been briefed on all aspects of the transfer and are willing to transfer.
3.
The area below the path of the carrier shall be kept clear of personnel.
9 .11
Cr ite ria
9 .11 . 1
C r ane S uita bi li t y
1.
The crane is certified.
2.
The certificate issued by the surveyor shall clearly indicate that the crane is suitable for personnel transfer (man-riding) and fully complies with the requirements of Lifting Operations and Lifting Equipment regulations (LOLER 19198) or ASME B30.23.
3.
SMEP Lifting Technical Authority must approve cranes for use in personnel carrier transfer duties, and shall review all certification and maintenance records pertaining to the crane.
4.
Loading hooks shall be of the design that can be closed and locked.
5.
All connections between the crane and the personnel carrier shall be such that they cannot be accidentally self-released under any circumstances.
6.
Cranes or winches, which are suitable for personnel lifting operations, shall be clearly marked at the operator’s location “SUITABLE FOR MAN RIDING” or “ SUITABLE FOR LIFTING PEOPLE”. Cranes with a capacity of less than 10 tonnes and/or winches with a capacity of less than 3 tonnes shall not be used for personnel lifting operations.
7.
Mobile cranes operating on marine vessels shall NOT be used for the transfer of personnel (refer to Section 11.5.5).
9 .11 .2
Per son ne l Tra nsf er Ca rri er
1.
The carrier shall be certified and be included in the ship’s Register of Lifting Gear.
2.
The certificate issued by the surveyor shall clearly indicate the carrier is suitable for personnel transfer.
3.
Personnel carriers must be of an approved design and approved by SMEP’s Lifting Technical Authority
Page 37 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
4.
Two tag lines shall be attached to the carrier, of a suitable length.
5.
There shall be no knots on the tag lines to minimise the chance of snagging.
6.
The transfer carrier lifting gear, master links, slings etc. shall have a factor of safety of at least 10. The carrier shall be equipped with a double safety load line assembly composed of a main wire rope sling and a secondary shock absorbing safety line. The capacity of the wire rope sling and the secondary shock absorbing safety line shall be such that either the sling or the safety line shall be able to carry the full load including the safety factor.
7. 8.
A length of 10metres is recommended for the pennant. The shackle type to be used is bow or anchor type fitted with split pins i.e. bolt, nut and split pin.
9.
An anti-spin device shall be fitted between the load and the personnel carrier upper master link. The anti spin device shall have a safety factor of at least 10 to 1.
10. 11.
The worksite supervisor shall perform inspections prior to each use. The carrier shall be thoroughly inspected every 6 months and load tested every 12 months or as recommended by the personnel carrier manufacturer.
NOTE: SCISSOR ACTION SPRING-LOADED OR SELF-LOCKING HOOKS SHALL NOT BE USED FOR PERSONNEL LIFTING OPERATIONS (REF. FIG. 16A)
9 .11 . 3 1.
V e s se l S ui ta bi li ty The type of vessel considered suitable to carry out a transfer is determined by its ability to maintain station alongside the platform and the amount of clear deck space available to safely receive the carrier.
2.
Vessels with an A-frame at the stern. Or without side railings are not considered suitable for carrier transfers. For SMEP this excludes the use of General Purpose mooring launches (Pilot Launches, Survey boats with A-frame and landing craft. Other vessels may also be found unsuitable depending upon station keeping ability and deck (obstruction) load status.
3.
Marine vessels used for personnel carrier transfer operations must be approved by the marine Technical Authority.
9 .11 .4 1.
T ake - off and la nd ing area The take-off and landing area shall be level, free from obstructions, and have a nonslip surface.
2.
The minimum clear space on the installation shall be 4.5metres by 4.5metres in any weather conditions.
3.
The minimum clear space on a vessel shall be 6 metres by 6 metres in any weather conditions.
4.
The minimum clear space with vertical obstructions must be as follows:
Page 38 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
(a) With a single vertical obstruction of 1.5 metres at the perimeter of the landing area, the clear area shall be 4.5 metres diameter. (b) With a single vertical obstruction of 2.5 metres at the perimeter of the landing area, the clear area shall be 7 metres in diameter.
9.12 9 .12 .1
Environmental W eath er
The weather criteria and maximum MOU or vessel movement for all personnel lifting operations shall be as follows: Mean wind velocity : 10 m/s measured at 10 metres above sea. Mean wind velocity
: 6m/s measured 10 metes above sea if working on the weather side.
Wave height
: Determined by the ability of the vessel to hold station.
Significant wave height
: Not more than 2 metres
Maximum roll (MOU)/vessel
: 3 degrees
The master of the attending vessel shall demonstrate that the above weather criteria are met at all times during transfer operations and shall demonstrate that the vessel can hold station within a 5 metre radius for at least 2 minutes prior to each transfer. SMEP marine department shall verify all sea state values.
9 .12 .2
Vi si bi li ty
Horizontal visibility must be considered and shall be a minimum of 500 metres. Vertical visibility shall be such that the tip of the crane boom is always in view by the crane operator. Approval from a level 4 manager must be obtained for any night time transfers.
9 .12.3
Daylig ht
Transfer operations, wherever possible, be conducted during daylight hours. In urgent cases, where night time transfers are felt unavoidable, the provision of searchlights to enable the crane operator to have adequate visibility throughout personnel transfer path and landing areas; the wearing of clothing with retro-reflective tape by those being transferred and recovery arrangements shall be addressed. A risk assessment shall be performed that shows that the risks are as low as reasonably practicable (ALARP).
For night time transfers, the weather criteria and maximum MOU or vessel movement for all personnel lifting operations shall be: Mean wind velocity
:
5 m/s measured at 10 metres above sea.
Significant wave height
:
Not more than 1.5 metres
Maximum roll (MOU)/vessel
:
3 degrees
Page 39 of 247
9 .12 . 4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
R ai nfa ll a nd Ele ctr i cal St or m s
If the transfer is proposed during a period of rainfall or electrical storm, considerations shall be given to the severity of the weather, and the transfer postponed if there are any concerns that it could affect the transfer. In all cases, when any of the above environmental conditions are exceeded all transfer activities shall cease immediately and transfer activities resume when environmental conditions return to an acceptable value.
9 .12 .5
Co mm u ni cat i o ns
Radio communication shall be established between Worksite Supervisor, Crane Operator, Master of the Vessel and Banksman. The Crane Operator radio communication shall be hands free, he shall have a full and unobstructed view of the take off and landing area as well as the full lifting trajectory. However the Banksman must be on hand to take control of signalling in the event that the crane operator loses visual contact with the “carrier”.
9 .13
P er son ne l
9 .13 .1
Cr ane or Win c h O per at or
The Crane Operator shall meet the competence requirements of Lifting Equipment Management System (EP200803208668)- and have a minimum of 50 operating hours (logged) operating the crane to be used in the personnel carrier operation. The crane or winch operator shall not leave the crane or winch controls throughout the duration of the personnel lifting operation. He shall solely concentrate his attention to the personnel lifting operation in progress.
9 .13 .2
B an k sman
The Banksman shall meet the competence requirements of Lifting Equipment Management System (EP200803208668) he shall be easily identified by a brightly coloured banksman jacket. He shall also carry a working radio by which to communicate as described in 9.12.5 above.
9 .13 .3
A ssi sti ng Per so nne l
Assisting personnel shall consist of two assistants at the take off and landing areas
9 .13 .4
Per son ne l Tra nsf er ri ng b y Carr ier
Personnel being transferred must be properly attired for offshore work i.e. safety helmet with chinstrap, safety footwear, safety glasses, long sleeved coveralls and approved floatation device. Have been briefed on the transfer procedure, viewed the transfer video and signed acceptance for transfer form. See Appendix 6. Personnel will only undertake the carrier transfer on a voluntary basis. If they do not wish to transfer, they must not be forced to do so.
Page 40 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
An experienced person shall always accompany an inexperienced person or those not trained in the use of the personnel carrier.
9 .14
B ag s
Hand luggage up to a maximum of 29kg (that can be strapped in place) may be transported inside the carrier. All other luggage, bags, oversized bags and tools shall be transported separately as cargo in a cargo box or other suitable container.
9 .15
T oolb o x Talk
Toolbox talks shall be held prior to the transfer, this will involve (crane side) the Person in Charge, Crane Operator, Banksman and assistants boat master via radio in necessary. Similarly, the boat Master shall brief his crew. The following elements of the transfer shall be included in the toolbox talk: •
Safe loading conditions
•
Crane actions, movements and signals
•
Body positions, pinch points and personal stability
•
PPE requirements
•
Safety aspects of the transfer – swing, escape routes etc.
•
Potential emergency situations and recovery/rescue procedures are in place
•
Expected behaviour of personnel being transferred.
9 .16
R e cover y Ar rang eme nts
A rescue plan shall be prepared for all personnel lifts as part of the Lift Plan. All personnel and equipment required to implement the rescue plan shall be readily available prior to and during the lift i.e. Fast Rescue Craft (FRC) must be on standby in the water to effect a speedy recovery if personnel fall into the sea. Rescue operations can introduce their own hazards, therefore the planning and execution of a rescue requires particular care and attention including additional risk assessment before proceeding.
9 .17
V e sse l Pr op e ller s
The lowering and hoisting of a personnel carrier near the propellers of a vessel to be avoided as much as is practically possible.
9 .18
P la nned Main te na nce
Refer to Section 4.
9 .19
A dmi ni stra ti on a nd Op era ti o nal Dut ie s .
Page 41 of 247
9 .19 .1
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
S ME P Sit e Rep re sen ta ti ve
The SMEP Site Representative shall be: 1.
Familiar with the carrier transfer requirements.
2.
Satisfied with the fitness and training of the personnel to be transferred.
3.
Satisfied with the suitability of the MOU.
4.
Satisfied with the visibility and sea conditions.
5.
Satisfied with the landing area
6.
Check the crane or winch and carrier have current valid Inspection Certificates.
7.
Check the crane or winch and carrier are registered and approved for personnel carrier transfer with SMEP Lifting Technical Authority.
8.
Check suitability of wind speed for crane operations.
9.
Ensure participants are briefed and understand the requirements of carrier transfer and have signed the transfer form.
10.
Ensure the Master of the vessel is familiar with the carrier transfer requirements and is briefed accordingly.
11.
Ensure that the Supervisors and Banksman are familiar with the carrier transfer requirements and handling of the carrier.
12.
Have verified the competency and experience of the crane operator.
13.
Ensure communications are established with all the parties involved in the transfer. The Master of the vessel, Officer supervising the boat desk, the crane operator and the supervisor on the installation.
14.
Verify the Fast Rescue Craft (FRC) cover is provided.
15.
Have carried out Risk Assessment.
16.
Authorise and sign the work permit, transfer request and transfer checklist for the carrier transfer.
9 .19 . 2
M a st e r o f t h e Ve ssel
Shall confirm to the SMEP site representative the following 1.
Must confirm boat is suitable for basket transfer and approved by Marine dept. and that he can hold station for the duration of the transfer in the prevailing weather and sea conditions.
2.
He accepts the transfer and understands the requirements for carrier transfer.
3.
Have confirmed that the deck crew understand the carrier transfer requirements and have been fully briefed.
4.
Two deck hands on deck to handle tag line.
5.
The Banksman is identified with a highly recognised vest and has a radio for communication and establishes communication on a dedicated channel.
6.
Confirm that the landing area is clear, and meets the landing area requirements
Page 42 of 247
Check
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
and is in a safe and clean condition. 7.
The people to be transferred have been briefed and signed the transfer form.
8.
Confirm that the person(s) transferring is/are fit to undertake the transfer.
9 .19 .3
B an k sman and /or De ck F or ema n
Shall confirm to the SMEP site representative the following 1.
The transfer requirements are understood
2.
The personnel carrier is checked, suitable for the transfer and is correctly rigged.
3.
The personnel transferring are fit for the transfer and understand the requirements; a demonstration of how to use the carrier will be given if required and signed the transfer form.
4.
Communications have been established.
5.
Have full view of the transfer areas.
6.
Landing area meets the requirements , is clear and is in a safe condition.
7.
The Banksman is clearly identified.
8.
Toolbox meeting held with all parties involved.
9.
2 riggers/deckhands to handle tag lines.
Check
10. Only certified and marked equipment is used in the transfer. 11. The personnel are wearing the correct PPE.
9 .19 .4
Cr ane Op era t or
Shall confirm to the SMEP site representative the following The crane is fully operational. The wind speed is satisfactory for safe operation for carrier transfer The requirements for carrier transfer have been
understood.
A full and unobstructed view of the Banksman and the transfer landing area on both sides. Confirm that the landing area is clear. Communications have been established. Daily crane checks have been completed and signed by the crane operator. The personnel carrier and lifting gear are in a safe state of repair before use. That the crane will carry no other load that the personnel carrier. That the logbook entry will be made for each lift. That he has no personal conflict with any of the personnel being lifted.
9 .19.5
Rigger s/Deck Hand s
Shall confirm to the Banksman/Deck Foreman the following: 1.
Have been briefed and understood the carrier transfer requirements.
2.
Familiar with handling the tag lines.
Page 43 of 247
Check
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3.
Know how to control the swing with the tag lines.
4.
Follow instructions from the Banksman/Deck Foreman in charge of the operation.
9 .19 .6
P er son ne l Tra nsf er ri ng
Shall confirm to SMEP site representative the following: 1.
Have been briefed and understand the carrier transfer requirements and signed the transfer form.
2.
Agreed to the transfer by carrier.
3.
Are physically fit and to declare if they suffer from Vertigo (fear of heights), seasickness etc.
4.
Understand that the transfer is purely on a voluntary basis.
5.
Familiar with the method of carrier transfer and has been briefed on the method of transfer.
6.
Observe all instructions from those in charge of the operation.
7.
Insist on being accompanied by an experienced person if transferring for the first time.
9 .19.7
Crane owner’ s Requirements
The owner of the crane used to transfer personnel in a transfer carrier shall ensure that: The crane is registered and approved for personnel basket transfer with SMEP’s Lifting Technical Authority. A logbook is available to enable the crane operator to make entries of each lift. This logbook must be made available for inspection on request.
9 .19 .8 1.
G e nera l Pr e cauti ons Moving the personnel carrier shall be only under powered conditions in a slow controlled, cautious manner.
2.
The load line hoist drum shall have controlled load lowering. Automatic brake shall apply in neutral position. Free fall is not allowed.
3.
The total weight including personnel transfer carrier, rigging and occupants shall not exceed 50% of the crane's rated capacity for the radius and configuration used.
4.
Rigging used for personnel hoisting must not be used for any other purpose and shall be kept apart from other rigging and clearly identified as only to be used for personnel hoisting.
5.
The rigging must be capable of handling 10 times the maximum intended load.
Page 44 of 247
9 .19 . 9
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Pr e -U se I n sp e cti o n
A pre-inspection of the personnel transfer carrier shall be undertaken at the start of each day the personnel carrier will be used. The pre-inspection shall be carried out in accordance with Work Instruction.
9 .19 .10
T ri al Li f t s
A trial lift with the unoccupied personnel transfer carrier shall be undertaken at the start of each day the personnel carrier will be used. After the trial lift and just prior to hoisting the personnel, the carrier and rigging shall be hoisted a few centimetres and inspected by the PIC.
Reflex Marine Frog transfer unit
9 .20
Esvagt-Rigid basket
Man R id ing (dr illi ng ope rati ons)
Manriding should always be avoided and alternatives should have been challenged. However if properly assessed and man riding will be required then only competent persons and dedicated Man Riding winches, which incorporate appropriate safety equipment, shall be used for Man Riding. These winches shall be clearly marked ‘DEDICATED FOR MAN RIDING’ and never used for any other purpose. A dedicated team including the PIC, Winch Operator, and person being lifted, shall carry out the operation. The PIC shall ensure that no other operation that could interfere with the Man Riding is carried out. Prior to installing or using winches that are certified for Man Riding the following shall be in place: 1.
A suitable and sufficient risk assessment shall be carried out to identify all reasonably foreseeable hazards and failure scenarios such that in all operations using Man Riding winches the person is protected from being crushed, trapped, struck or falling from the carrier. Measures additional to those mentioned in this Section shall be put in place if the risk assessment identifies circumstances in which additional controls are required;
2.
Emergency means shall exist by which all winch motion can effectively and rapidly be brought to a halt;
Page 45 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
A comprehensive review shall be made by the PIC to ensure that the safety features of the winch are adequate to provide a safe method of operation for the Man Riding operation. No Man Riding shall be allowed if the Winch Operator does not have clear sight of the rider. Man Riding below the derrick floor level is not allowed. It requires a separate Man Riding winch mounted below the floor. Man riding above the monkey board level shall not be permitted.
Use of Man Riding harnesses shall only be allowed for short durations with authorisation of the Site Manager. Refer to (Yellow Guides) ‘Working at Height’ for maximum permissible times and recovery periods. The maximum time suspended in the Man Riding harness must always be determined in the risk assessment, taking into account manufacturers instructions, gender and physical condition of the manrider. Only full body harnesses shall be used. Harnesses shall never be used for lifting personnel for long duration jobs, as the potential exists for constricting the blood supply vessels in the legs. A secondary fall protection device shall be used, independent of the primary lifting mechanism. A split pin shall be used on the shackle between riding belt and winch wire. It shall not be possible for the split pin to fall out during use. Other types of pin shall not be used. Use, maintenance, storage, check, inspection and examination of riding belts shall as a minimum comply with manufacturer’s instructions for use, see also EN 813 and EN 365.
9 .20 . 1
W in che s f or Ma n Ri ding
Winches that are to be used for Man Riding shall have the following features and settings: 1.
A second independent brake shall be provided for use if the automatic brake fails. This brake should be manual unless the second automatic brake is completely independent of the automatic braking system;
2.
Equipment shall be incorporated in the winch system to prevent the carrier from overriding and over speeding;
3.
Maximum pull limiting feature. The limit shall be set to the value determined during the risk assessment for the job;
4.
The winch shall be capable of lowering in a controlled manner in the event of sudden loss of power or primary control;
5.
The winch shall have adequate capacity to handle the loads required which should include but not be limited to: 1.
Weight of passengers;
2.
Tare weight of the carrier;
3.
Rope weight and frictional effects.
Page 46 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The design factor for the winch and the wire rope, taking into account the sum of these weights, shall not be less than 8:1. 6.
Suspension points for sheaves in the winch systems shall be rated to withstand the maximum credible winch pull;
7.
The design of the winch should be supported by a FMEA (Failure Modes and Effects Analysis);
8.
The winch shall be equipped with a guard over the drum that provides protection to the Winch Operator e.g., in the event of rope breakage, but does not inhibit the operator from monitoring the spooling action of the rope on the drum;
9.
Wire rope used in Man Riding winches shall be of the non-rotating type or as identified by the manufacture;
The ratio (D/d) between sheave diameter (D) and the wire rope diameter (d) shall not be less than 22.
Page 47 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
10.0 Suspended Work Baskets (Cranes) Suspended workbasket operations are not the preferred method of carrying out work at elevated heights. However, it is recognised that there are situations where this method of operation may be justified; suspended workbasket operations offshore are forbidden. All suspended workbasket operations must be covered by an appropriate SMEP Shell Permit to Work, Risk Assessment and Lift Plan, and be conducted in accordance with this standard. The following information is based on the guidance given in: 1.
LOLER 98, Reg 5
2.
ASME B30.23
3.
HSE Safety Notice 1/97
1 0 .1
R equir e ment s
The following covers the basic safety requirements that must be met when personnel are required to work from a ‘suspended work basket’ that has been raised by a mobile crane.
1 0 .2
Eq uipm ent
All lifting tackle used in the lift must have safety coefficient of at least twice that required for general lifting. The workbasket and associated lifting equipment and lifting tackle must be marked with its respective SWL, identity and correct colour code. All lifting equipment and lifting tackle to be used in the operation must be pre-use inspected. The crane shall be uniformly level within 1% of level and shall have firm footing under both crawler tracks or all outrigger pads. Where a crane is used that has load-limiting and/or slack wire cut-out device, the correct operation of these devices must be confirmed before the crane is used. Before starting the operation ensure that the wire rope is spooled correctly on the drum. If the operation Risk Assessment identifies that there is danger from falling objects, or a danger of striking overhead objects as the ‘suspended workbasket’ is raised, suitable overhead protection for personnel in the carrier must be provided. If the workbasket has access doors they must open in-wards and must have a device to prevent inadvertent opening. Suitable high edge guardrails must be fitted to the workbasket to prevent personnel from falling from the workbasket. The floor of the workbasket must have a non-slip surface. To cover the event of a failure to the primary lifting system with personnel suspended, a secondary system capable of safely lowering the workbasket, or personnel from the workbasket, must be available. Where appropriate warning labels must be attached to equipment to indicate known dangers. Labels shall also be fitted to warn against incorrect usage.
1 0 .3 1.
P er s on ne l All personnel involved in suspended workbasket operations must have:
Page 48 of 247
2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
a.
Agreed to do so.
b.
Have received adequate instruction.
c.
Be fully conversant with the requirements involved.
Confirm that all personnel in the workbasket are wearing appropriate Personal Protective Equipment (PPE).
3.
The Risk Assessment must consider the practicability of issuing personnel with fall arresters anchored on the workbasket safety anchorage points.
4.
Personnel in the workbasket must have a primary means of communication/attracting attention (e.g. hand-held radio) and a back-up system (e.g. whistle) if assistance is required.
1 0 .4
P e r s on ne l E n g a g e d i n S u sp e nd e d Wor k Ba sket Activ iti es (O nsh ore O nl y)
1 0 .4 . 1
A ut hori ty
All suspended workbasket operations shall only be carried out using the SMEP Permit to Work system. To support the issuance of the permit to work, the attached suspended workbasket operations checklist shall be utilised for each individual operation (Appendix 6). For guidance on how to complete the work permit refer to DIN: TCP.XX.1009, “Permit to Work System”.
1 0 .4 . 2
Pr e requi sit e s
If a suspended workbasket operation is to be carried out the following must be produced before the operation can start: 1.
Permit to Work.
2.
Risk Assessment.
3.
Lift Plan. (Written step-by-step instructions)
4.
Safety Check List.
1 0 .4 . 3
R is k A s se s sme nt
All suspended workbasket operations must be subject to a risk assessment (Refer E95-0311) and a lift plan. The risk assessment shall identify all reasonably foreseeable hazards and failure scenarios such that in all suspended workbasket operations the people are protected from being crushed, trapped, struck or falling from the workbasket. Appropriate crane and work basket checks to be recorded in the plan. A person in charge (PIC) shall carry out the checks and supervise the operation defined in the lift plan.
Page 49 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
1 0 .4 . 4 1.
Ot he r C onsi der at i ons To prevent personnel from walking beneath the suspended workbasket the area beneath the workbasket must be cordoned off.
2.
That other criteria required for the operation are met, e.g. personnel are wearing full body harness, and they have been briefed on all facets of the operation.
1 0 .5
C r ite ria
1 0 .5 . 1
C r ane S uita bi li t y
1.
A lifting surveyor from an independent third party certification authority shall certify the crane.
2.
The certificate issued by the lifting surveyor shall clearly indicate the crane is suitable for man-riding and fully complies with the requirements of ASME B30.23 or Lifting Operations and Lifting Equipment Regulations (LOLER 1998).
3.
SMEP’s Lifting Technical Authority must approve cranes used for suspended workbasket operations and shall review all certification and maintenance records pertaining to the crane.
4.
Load hooks shall be of the design that can be closed and locked. The mousing of the hook opening is not permitted.
5.
All connections between the crane and the suspended workbasket shall be such that they cannot self-release under any circumstances.
6.
Articulating or truck loading cranes (HIAB trucks) are not suitable for man-riding duties and shall not be used,
Cranes, which are suitable for personnel lifting operations, shall be clearly marked at the operator’s location “SUITABLE FOR MAN RIDING” or “SUITABLE FOR LIFTING PEOPLE”. Cranes with a capacity of less than 10 tonnes shall not be used for suspended workbasket operations.
1 0 .5 . 2 1.
W or k Ba s ket s A surveyor from an independent third party certification authority shall certify the workbasket.
2.
The certificate issued by the surveyor shall clearly indicate the workbasket is suitable for suspended work activities.
3.
SMEP’s Lifting Technical Authority must approve the work basket used and shall review all certification and maintenance records pertaining to the work basket.
4.
The purpose-built workbasket shall be designed to an International Standard i.e. BS EN 14502-1, AS 1418 or ASME B30. 23 or equivalent.
5.
Two taglines shall be attached to the workbasket, of a suitable length.
6.
There shall be no knots on the tag lines to minimise the chance of snagging.
Page 50 of 247
7.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The workbasket lifting gear, master links, slings, etc. shall have a factor of safety of at least 10. The workbasket shall be equipped with a double safety load line assembly composed of a main wire rope sling and a secondary shock absorbing safety line. The capacity of the wire rope sling and the secondary shock absorbing safety line shall be such that either the sling or safety line shall be able to carry the full load including the safety factor.
8.
The shackle type to be used is the bow or safety-anchor type fitted with split pins, that is, bolt, nut and split-pin.
9.
An anti-spin device shall be fitted between the load line and the workbasket upper master link. The anti spin device shall have a factor of safety of at least 10 to 1.
10. 11.
The worksite Supervisor shall perform subsequent inspections prior to each use. The workbasket shall be thoroughly inspected every six months and load tested every twelve months or as recommend by the workbasket manufacturer.
NOTE: SCISSOR ACTION SPRING-LOADED OR SELF LOCKING HOOKS SHALL NOT BE USED FOR PERSONNEL LIFTING OPERATIONS. REFER FIG 16.
1 0 .6
E nvi ronm e nta l Cond itions
1 0 .6 . 1
W eath er
The weather criteria for all personnel lifting operations shall be as follows: Mean Wind Velocity
:
8 m/s measured at 10 metres above ground level.
The person in charge shall ensure that the above weather criteria is fully met at all times during the operation.
1 0 .6 . 2
V i si bi li ty
Horizontal visibility shall be considered, and shall be at least 500 metres. Vertical visibility shall be such that the tip of the crane boom is always in full view by the crane operator.
1 0 .6 . 3
D ay l ig ht
Workbasket operations shall only be carried out during daylight hours.
1 0 .6 . 4
R ai nf a l l & Elec t ri ca l St or m s
If the workbasket operation is proposed during a period of rainfall or electrical storm, consideration shall be given to the severity of the weather, and the operation postponed to more favourable conditions if there are any concerns that it could effect the operation. In all cases, when any of the above environmental conditions are exceeded, all activities shall cease immediately, and workbasket activities may only resume when the environmental conditions return to acceptable values.
Page 51 of 247
1 0 .7
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
C o mm u ni cat i o ns
Radio communication shall be established between Person in Charge, Crane Operator (hands free), Banksman and the lifted personnel. The crane operator shall have a full and unobstructed view of the workbasket operating area.
1 0 .8
C r ane
The Crane Operator shall hold a current, valid mobile crane operator's certificate, from a SMEP approved training provider, and have a minimum of 6 months experience as a crane operator. The Crane Operator shall also have a minimum of 50 operating hours (logged) operating the crane to be used in the suspended workbasket operation. The crane operator shall not leave the crane controls throughout the duration of the suspended workbasket operation. He shall solely concentrate his activities on the suspended workbasket operation in progress.
1 0 .9
P er s onne l
1 0 .9 . 1
B an k sman
The Banksman shall hold a current, valid banksman’s certificate from a SMEP approved training facility and have experience of workbasket lifting operations. The banksman shall be easily identified by a brightly coloured banksman’s jacket. They shall also carry a working radio by which they can communicate as described under 9.4 “Communications” above.
1 0 .9 . 2
P er s on ne l W or king f ro m t he W ork Ba ske t
Personnel working from the workbasket must be properly attired this includes safety helmet with chinstrap, safety footwear, coverall and approved full body harness. Personnel will only undertake work on a voluntary basis. If they do not wish to work from the workbasket, they will not be forced to do so. See Appendix 6 An experienced person shall always accompany inexperienced people or those not trained in the use of suspended workboxes.
1 0 .10
T oo l Ba g s
Only the required tools and materials required to carry out the task shall be allowed in the workbasket.
1 0 .11 Saf e ty 1 0 .11 .1
T oo l b o x Ta lk
Toolbox talk shall be held prior to the personnel being hoisted, this will involve the Person in Charge, crane operator and personnel to be hoisted the following elements of the operation shall be included in the toolbox talk:
Page 52 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
•
Crane actions, movements and signals.
•
Body positions, pinch points and personal stability
•
Personnel protective equipment requirement
•
Safety aspects of the operation – Basket swing, Escape routes etc.
•
Potential emergency situations
•
Expected behaviour of personnel being hoisted
1 0 .11 .2
R e c ov ery Ar ra ng eme nts
A rescue plan shall be prepared for all personnel hoisting operations. All equipment required to implement the rescue plan shall be readily available prior to and during the operation. Rescue operations can introduce their own hazards; therefore the planning and execution of a rescue requires particular care and attention including additional risk assessments before proceeding.
1 0 .12
M ai n tena n ce
1 0 .12 .1
P l a nne d ma in te nan ce
To ensure safe and satisfactory operation of the crane and workbasket, a properly planned maintenance system shall be established and used. Refer to IMP 0.03 Lifting Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032) for further details.
1 0 .13
A dmi ni stra ti ve a nd Op era ti o nal Dut ie s
1 0 .13 .1
P er s on i n Cha r ge
1.
Familiar with the suspended workbasket requirements.
2.
Satisfied with the fitness and training of the people to be work from the work basket
3.
Satisfied with the visibility.
4.
Check the crane and workbasket have current valid Inspection Certificates.
5.
Check the crane and workbasket are registered and approved for workbasket operations with SMEP’S Lifting Technical Authority.
6. 7.
Check suitability of wind speed for crane operations Ensure participants are briefed and understand the requirements for workbasket operations.
8. 9.
The Banksman is clearly identified. Ensure that the Supervisors and Banksman are familiar with the workbasket operation requirements and handling of workbaskets.
10.
Have verified the competency and experience of the crane operator.
Page 53 of 247
11.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ensure communications are established with all parties concerned for the workbasket operations.
12.
Toolbox meeting held with all parties involved.
13.
Personnel are wearing the correct PPE.
14.
Carry out Risk Assessment
15.
Authorise and sign the work permit.
1 0 .13 .2
B an k sman
Shall confirm to the Person in Charge the following: 1. The work basket operations requirements is understood 2. The workbasket is checked, suitable for the operation and is correctly rigged. 3. Have confirmed the personnel working from the workbasket are fit and understand the requirements; a demonstration of how to use the workbasket will be given if required. 4. Communications have been established on a dedicated radio channel. 5. 2 riggers to handle the tag lines.
1 0 .13 .3
C r ane Dri ver
Shall confirm to the Person in Charge the following:
Check
1. The crane is fully operational. 2. The environmental conditions are satisfactory for safe operation for the suspended workbasket. 3. The requirements and requirements for suspended workbasket operations have been understood. 4. A full and unobstructed view of the Banksman and the workbasket operating area. 5. Hands free communications have been established. 6. Daily crane checks have been completed and signed by the crane driver. 7. The workbasket and lifting gear are in a safe state of repair before use. 8. That the crane will carry no other load than the workbasket. 9. That the logbook entry will be made for each lift.
1 0 .13 .4
R ig ger s
Shall confirm to the Banksman the following: 1. Have been briefed and understand the suspended workbasket requirements. 2. Familiar with handling the tag lines. 3. Know how to control the swing with the tag lines. 4. Follow instructions from the Banksman.
Page 54 of 247
Check
1 0 .13 .5
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
P er son ne l W or king fro m a W or kba sket
Shall confirm to the Person in Charge the following:
Check
1. Have been briefed and understand the suspended workbasket requirements. 2. Agreed to the work from the suspended workbasket. 3. Are physically fit and to declare if they suffer from Vertigo (Fear of height), etc. 4. Understand that the work is purely on voluntary basis. 5. Familiar with the method of suspended workbasket operations. 6. Observe all instructions from those in charge of the operation. 7. Insist on being accompanied by an experienced person if working from a suspended workbasket for the first time.
1 0 .13 .6
Cr ane Ow ner ’ s R equir emen ts
The owner of the crane used to suspended workbasket shall ensure that: 1.
The crane is registered and approved for personnel basket transfer with SMEP’s Lifting Technical Authority.
2.
A logbook is available to enable the crane operator to make entries of each lift.
3.
This logbook must be made available for inspection on request.
1 0 .13 .7 1.
G e nera l Pr e ca uti on s
Moving the suspended workbasket shall be only underpowered conditions in a slow controlled, cautious manner.
2.
The load line hoist drum shall have controlled load lowering. Automatic brake shall apply in neutral position. Free fall is not allowed.
3.
The total weight including suspended workbasket, rigging and occupants shall not exceed 50% of the cranes rated capacity for the radius and configuration used.
4.
Rigging used for personnel hoisting must not be used for any other purpose and shall be kept apart from other rigging and clearly identified as only to be used for personnel hoisting.
5.
The rigging must be capable of handling 10 times the maximum intended load.
Page 55 of 247
1 0 .13 .8
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
C a rr ier Pre- use I n spe ct i o n C he ck
Longer leg Slings must be fitted with a high visibility cover
The shackle type to be used is the bow or anchor type fitted with split pins, that is, bolt, nut and split-pin.
Slings are correctly attached and in good order
NOTE: CHECK SAFETY HARNESS ATTACHMENT POINTS ARE SECURE.
1 0 .13 .9 1.
T ri al Lif t s
A trial lift with the unoccupied work basket carrier loaded with ballast at 1.25 times the intended load, including personnel, shall be undertaken at the start of each day the suspended work basket will be used.
2.
After the trial lift and just prior to hoisting the personnel, the workbasket and rigging shall be hoisted a few centimetres and inspected by the PIC.
Page 56 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
11.0 Use of Mobile Cranes on Marine Vessels 1 1 .1
P urp o se
It is not Shell Malaysia Exploration and Production (SMEP) practice to allow the use of mobile cranes on marine vessels, however their use may be allowed when the requirements of this standard are strictly adhered to. This section provides the requirements which shall be followed when using a mobile crane on a marine vessel. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-G01 (section 4 page 15)
1 1 .2
S c op e
The scope of this section covers the use of mobile cranes mounted on marine vessels. These types of arrangements shall be considered as a floating crane. The position of the crane on the marine vessel affects the trim and stability of the combination, and this has to be taken into account. This section specifies the minimum requirements for the marine vessels listed below, however, the list is not exhaustive. It is the duty of the Contract Holder to ensure that any marine vessel where lifting operations are undertaken offshore, has equipment which complies with the marine vessels classification society’s rules and this manual. Examples of marine vessels where this section will apply: 1.
Pipe laying ships and barges.
2.
Crane barges, work barges
3.
Dredgers, using cranes with clam shells or buckets.
Examples of marine vessels where this section will not apply: 1.
Supply/Anchorhandling vessels and stand-by vessels
2.
Shuttle tankers
3.
Dredgers, except those fitted with cranes using clam shells or buckets
4.
Survey vessels
5.
Jack up rigs
6.
Drilling Vessel
1 1 .3
Req uire m ent s
1 1 .3 . 1
C r ane S uita bi li t y
It shall be noted that mobile cranes are particularly sensitive to external influences such as environmental effects, vessel movements, and dynamic loading. There are several types of mobile cranes, initially designed for land-based operations, which can be considered for lifting operations offshore. Not all however are equally suitable, e.g., a wheel-mounted crane, will
Page 57 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
not be suitable, because of tyre floatation effects and shorter wheelbase. It is not as stable as a tracked/crawler crane for the same duty and/or operating conditions. The suitability of a mobile crane for use on a marine vessel shall therefore be carefully appraised according to service requirements, type of marine vessel and operational requirements.
Mobile cranes require to be certified in accordance with the latest revision of IMP 0.03 Lifting Equipment, SMEP.EP72.ST.0032. It shall be noted that the certification and load-testing of the mobile crane, shall include verification that tie downs, supports, ballast counterweight and load radius configuration conform to the crane manufactures or an authority experienced in crane design and stability of craft specifications. Certification and load-testing of the mobile crane must be undertaken after the crane has been mounted on the marine vessel and prior to utilisation in Malaysia; the certification and load-testing of the mobile crane requires to be undertaken by a third party surveyor from a classification society and witnessed by SMEP’s Lifting Technical Authority. Subsequent certification of the mobile crane shall be at the time intervals detailed in IMP 0.03 Lifting Equipment, SMEP.EP72.ST.0032, witnessing of these certifications by SMEP’s Lifting Technical Authority is not required. .
1 1 .3 .2
T ype s of Mobi le Cranes
Mobile cranes that feature all hydraulic power transmission, integrated control systems, enclosed gear drives and brakes are preferred opposed to mechanically driven cranes using open gear drives and open brakes/clutches. TABLE 1 outlines in general terms, the prospective suitability of various types of mobile cranes for use on barges.
TABLE 1 Monohull. TYPE OF MOBILE CRANE & MODE OF USE
Sea lifts
Inboard lifts
Wheel mount - free lifting/travelling on tyres
NP
NP
Wheel mount - free on outriggers
NP
NP
POSS
POSS
YES
YES
POSS
POSS
Crawler crane - tied-down
YES
YES
Crawler crane - fixed chassis
YES
YES
Wheel mount - outriggers tied-down Wheel mount - fixed chassis Crawler crane - free lifting / travelling on tracks
NP
Not Permitted
YES
Preferred option
POSS
Possible option, where a risk assessment has been performed that shows that the
risks are as low as reasonably practicable (ALARP).
Page 58 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The risk assessment shall be appraised by the contractor and the executing department and submitted to SMEP’s HSE department and Lifting Technical Authority for review. Other factors for consideration when selecting mobile cranes for use offshore are as follows: •
Cranes, which operate with outriggers deployed, shall have the facility to withstand any high pressure generated in the outrigger's hydraulic system, arising from dynamic lifting operations.
•
Booms shall have adequate torsional stiffness, rigidity and lateral stability for the service specified. Box section booms of the type used on ram luffing/telescoping cranes are not considered suitable.
•
Mobile cranes fixed, tied-down or pedestal mounted shall still be considered as mobile cranes.
NOTE: ALL OTHER TYPES OF MOBILE CRANES ON MARINE VESSELS, WHICH ARE NOT INCLUDED IN THE CLASSIFICATION SOCIETY REGISTER OF LIFTING GEAR, OR ARE NOT COVERED BY THIS STANDARD, WILL BE CONSIDERED BY SMEP'S LIFTING TECHNICAL AUTHORITY ON A CASE-BY-CASE BASIS. THEY SHALL BE STRICTLY APPRAISED IN ACCORDANCE WITH THIS SECTION.
1 1 .3 . 3
C r ane Ca pa ci ty
The capacity charts displayed in the operators cab shall clearly show the maximum crane list the crane can safely operate at. The charts will reflect the type of crane mounting and operating conditions i.e. static or dynamic lifting. •
Capacity charts supplied for a fixed mobile crane shall be based on structural strength.
•
Capacity charts for a deck-mounted crane shall be based on stability (tipping).
It is preferable to have crane capacity charts based on allowable crane list supplied by the crane manufacturer. Where this is not possible, an authority experienced in crane design and stability of craft shall provide capacity charts and the maximum amount of crane list the charts are applicable for. The capacity charts shall be confirmed and approved by the marine vessel’s Classification Society, Naval Architect or Warranty Surveyor. The crane’s load indicator shall be recalibrated to reflect the crane’s reduced capacity charts.
1 1 .3 . 4
C r ane S ta bi li t y f or D ec k M oun ted Cra ne s
The minimum stability margin for a deck-mounted crane shall be 1.33 X the safe working load. Stability testing of the deck-mounted crane shall be carried out if the crane has been de-rated from its land-based duties to achieve a stability margin of 33%.
Page 59 of 247
1 1 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
W ea th er Cr it eri a a nd M ob il e Of f shor e U nit (MOU ) Sta bili ty
1 1 .4 . 1
W eath er Cri ter ia A nd M o bi le Off sh or e U ni t Sta bi li t y
The weather criteria and maximum MOU movement for all mobile cranes on marine vessel operations shall be as follows: Mean wind Velocity
:
10 m/s measured at 10 metres above the sea
Significant wave height
:
of not more than 2 metres, and a 3° roll and 2 deg pitch of the vessel. (on site conditions NOT weather forecast data)
Maximum list
:
as advised by the crane manufacturer or the authority experienced in crane design and stability of craft.
The master of the marine vessel or attending marine vessel shall demonstrate that the above weather criteria are met at all times during lifting operations. The contractor shall liaise with the CSR on site who in turn, will liaise with the SMEP Marine Department of to confirm the sea state values. In all cases when the above sea state values are exceeded the mobile crane shall have the boom lowered onto the boom rest. Crane activities can only resume when the sea states fall below the above stated values.
1 1 .5 1 1 .5 . 1
M ob il e Cra n e s Ti ed - D ow n, Fr ee Lift i ng a nd Tra vel li n g W it h L oad V e s se l de ck Str e ngth
The vessel’s Classification Society or Naval Architect shall verify that the vessel’s deck is strong enough, under all operating conditions and the cranes operating area for the use of the proposed mobile crane. The deck structure of the marine vessel and any mats/bearers used, shall be adequate to support all forces generated by the operation and test loading of the crane including: The maximum force that would cause the crane to tip. a. b.
Tractive forces i.e., forces to propel/travel the crane. Braking forces when arresting travelling and/or slewing and, decelerating the load hoist and boom.
c.
Dynamic forces including any forces arising from offleads/sideleads
d.
Forces generated by steering and spragging of the crane.
e.
Forces induced by any motion of the barge.
1 1 .5 . 2
M o bi le cr an e s ti ed-d ow n
Mobile crane’s operating on a marine vessel, require to be tied-down or fixed at dedicated locations on the deck. The location of the tie-down points on the crane/marine vessel and, the method of fixing via welding, bolting, turnbuckles etc., shall be agreed between the marine vessel’s Classification Society or Naval Architect and the crane manufacturer/supplier. The
Page 60 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
crane supplier shall verify that the method used to fasten or restrain the crane to the deck is strong enough, under all operating conditions to prevent the crane from breaking off the deck or moving on the marine vessel. The supplier shall provide a critical assessment of the strength and failure mode sequence of the tie-down points and of the crane’s primary load path elements including as appropriate; boom, A-frame, bedplate, car body, chassis, outriggers, hydraulic rams (luffing and outriggers), slew bearing and fasteners and all primary load carrying pins. The calculations of all forces transmitted to the marine vessel’s structure and the sequence of failure report in conjunction with the lift programme that the mobile crane is intended to be used for, shall be assessed and approved by the marine vessel’s Classification Society, Naval Architect or a SMEP recognised warranty surveyor. The crane supplier shall provide copies of the approved calculations and the sequence of failure report to SMEP’s Lifting Technical Authority for review. All crane tie-down welds to be subjected to 100% volumetric and surface inspection methods prior to utilisation in Malaysia. The crane tie-down welds shall be subject to 100% visual inspection every six months and 100% volumetric and surface inspection annually.
1 1 .5 . 3
M o bi le cr an e s f r ee l if ti n g
Because of the particularly large and random motions of monohull marine vessel’s arising from wave action, the use of mobile cranes for free lifting shall not be SMEP’s preferred option. However, where cranes are required to free lift, the crane must work on a timbered area and have travel restrained by side constraints and end stops. When not working, the crane chassis is required to be anchored with tie-downs to the deck and the boom lowered on to a boom rest. Where cranes are required to free lift, particularly when the motion of the marine vessel can cause the load to pendulum and adversely affect the stability of the crane. A risk assessment shall be performed that shows that the risks are as low as reasonably practicable (ALARP). SMEP's Lifting Technical Authority shall carefully consider free lifting on a case-by-case basis, only after approval has been granted by SMEP’s Lifting Technical Authority shall work commence. The supplier shall provide a critical assessment of the cranes stability, based on the weather criteria and maximum MOU movement detailed in Para 10.5. The calculations of all forces transmitted to the marine vessel’s structure and the critical assessment, shall be assessed and approved by the marine vessel’s Classification Society, Naval Architect or a SMEP recognised warranty surveyor. The crane supplier shall provide copies of the approved calculations and the critical assessment report to SMEP’s Lifting Technical Authority for review. The supplier shall ensure that the provision of any mats, bearers etc. used to spread these forces are positively and effectively secured to the deck of the marine vessel. Any mats/bearers used to carry the load across the deck of the barge shall not deviate, move, spread or cause any de-stabilising effects under any operating condition and, under any forces arising from Section 10.6.1 a), b), c), d), e) and f).
1 1 .5 .4
Mobi le cr an e s tr ave llin g wit h load
However, where cranes are required to travel with the load, they must fully meet the requirements of 10.6.3 and be shown to be ALARP.
Page 61 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
SMEP's Lifting Technical Authority shall carefully consider cranes travelling with load on a case-by-case basis, only after approval has been granted by SMEP’s Lifting Technical Authority shall work commence. On wheel mounted cranes, the effects of tyre floatation will add to the pendulum problem. Wheel mounted cranes shall not be considered suitable and are therefore not permitted. (refer table 1).
1 1 .5 .5
Mobi le cr an e s used for ba sket tr an sfer
Mobile cranes operating on marine vessels shall NOT be used for the transfer of personnel.
1 1 .5 . 6
Pr o ced ur e s
The contractor shall provide a procedure for the safe use of the mobile crane on the marine vessel. The procedure shall fully comply with this standard and shall be forwarded to SMEP’s Lifting Technical Authority for review and approval.
1 1 .6
Docume nta t i on
All records shall be in accordance with IMP0.03 Lifting and Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032)
1 1 .7 1 1 .7 . 1
P eri od i c Che ck s G e nera l
The Chief engineer shall ensure that the checks given in 10.8.2 to 10.8.3 have been carried out. NOTE. It is possible the crane operator could be authorised to carry out periodic checks, to the extent that he may be considered competent.
1 1 .7 . 2
C r ane Pre- st art C he cks
Carry out the following pre-start checks: 1.
Carry out pre-start checks following the Manufacturer’s checklist. This must include (as a minimum) a check of oil, coolant and fuel. If the crane engine requires refuelling refer to Para 13.11.7. Walk round the crane and the crane access ways, visually checking for any faulty conditions or abnormalities. The checks must include audible warning devices, all safety limits and cut outs, boom, hook blocks, sheaves, wire ropes and pendants (including spooling of wire rope on to the drums, rope terminations and any anchorage points), cab, control levers, slew motors, pinions and brakes.
2.
Check that the rated capacity indicator is set for it’s correct duty and that the daily test is carried out.
3.
Check that there are no obstructions in the travel of the crane.
4.
Condition of tie downs.
Page 62 of 247
5.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
If the crane cannot operate, post a “DO NOT OPERATE” sign in a prominent position at the crane’s controls and if necessary, in the machinery/engine room.
6.
Any faulty condition shall be reported.
7.
All acceptable conditions shall be recorded.
1 1 .7 . 3
R ep ort in g of d efe ct s a nd i n ci dents
The Person in Chargeshall ensure the CSR and the project engineer are immediately notified of the following: 1.
Any defects found during daily or weekly checks.
2.
Defects found at any other time.
3.
Incidents or accidents, however slight
4.
Shock loads, however they occur.
5.
Dangerous occurrences or reportable accidents.
1 1 .8
M ain te na nce
1 1 .8 . 1
G e nera l
Provision shall be made to ensure that throughout its use the crane, tie-downs and other equipment used in the lifting operation are maintained in a satisfactory condition. The appointed person shall be satisfied that adequate information, e.g. manufacturer's instructions, are available and that the maintenance is carried out by trained personnel who have adequate knowledge of the correct procedures. The frequency and extent of such maintenance shall take account of all factors that affect the crane in carrying out its work.
1 1 .8 .2
P la nned ma in te na nce
To ensure safe and satisfactory operation of the crane and workbasket, a properly planned maintenance system shall be established and used. Refer to IMP 0.03 Lifting Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032) for further details.
Page 63 of 247
12
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fork Lift Trucks
1 2 .1
G e nera l
Forklift trucks, in a range of different capacities, are used for handling goods in SMEP worksites. Forklift trucks must be equipped with a protection device that protects the operator in case of rollover. The wearing of the seat belt is obligatory. A bright orange revolving light shall be installed and must operate automatically while the forklift truck is in use. An automatic acoustic reversing drive alarm shall be installed. Only properly trained and certified people are allowed to operate forklift trucks within SMEP worksites. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-G01 (section 9 page 20)
1 2 .2
Pr e-U se
At the start of every shift it is the forklift operator’s duty to carry out a visual check on the truck to ensure it is in a safe condition. As a minimum the following checks shall be made:
1 2 .2 . 1
S ta rt v ehi cle in sp e ct ion
1.
Overhead guard for security.
2.
All hydraulic rams and cylinders and hoses for leaks.
3.
Mast assembly for wear.
4.
Lift chains and rollers for wear and damaged links, ensure anchors are secure.
5.
Forks, ensure they are not bent or damaged, lateral locks are present and working.
6.
Condition of the wheels and tyres.
7.
Check fuel level and fuel gauge.
8.
Check seat belt condition and operation, including anchorages.
9.
Check the engine oil level.
10.
Check the engine coolant level.
11.
Check the transmission fluid level.
12.
Check the hydraulic fluid level.
13.
Check the battery condition.
1 2 .2 . 2
I g nit i o n ON c hec k s
Check/Test the standard equipment: 1.
Front, tail, and brake lights.
2.
Fuel gauge (if diesel).
Page 64 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3.
Rated Capacity Indicator (if fitted).
4.
Amber warning light.
5.
Windshield wiper, if fitted.
6.
Acoustic reversing alarm.
1 2 .2 . 3 1.
E ng in e R unni ng C he cks Check the gauges. a.
Oil pressure gauge.
b.
Ammeter indicator lamp.
c.
Hour meter.
d.
Water temperature gauge.
2.
Steering
3.
Brakes
4.
Horn
5.
Lights
6.
Check the operation of any load-handling attachments, rotator etc.
1 2 .2 . 4
Pr e -u se c h e c k s f or f or k li f t t r uc k s no t i n u se f or a n e x ten d e d p eri od of time
In cases where a forklift truck is not used for an extended period of time the user shall ensure that the person in charge specifies a special programme of pre-use checks and in-service inspections and thorough examination before it is used. The extent and thoroughness of this programme depends not only on the length of the period that the fork lift truck was out of use but also on the location of the fork lift truck during this period. Forklift truck’s standing under cover or inside a workshop might require very little extra inspection. Forklift truck’s that have been out of use in the open and therefore exposed to the weather and atmospheric pollution, etc. might require an extensive appraisal to ensure fitness for work. The programme of pre-use checks and in-service inspections must contain, as a minimum, the following checks: 1.
Any checks that are recommended in the manufacturers instructions for the forklift truck.
2.
Checking all hoist chains for signs of corrosion/degradation and damage and ensuring that there is thorough lubrication.
3.
Checking all control linkage for evidence of seizure or partial seizure and ensuring that there is correct lubrication.
4.
Checking for correct functioning of all the safety devices.
5.
Checking hoses, seals or other components for evidence of deterioration.
6.
Checking for corrosion on the structure, access, control linkages etc.
7.
Checking for structural integrity, for example cracks, dents, missing components.
Page 65 of 247
8.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Testing of every motion without load, each motion individually at first then by combination of two or more motions simultaneously as appropriate, and then repeating the test with a load.
1 2 .2 . 5
D o cu me nt s
The following documents must be present on the forklift truck: 1.
The current certificate of examination.
2.
The safe working load chart.
1 2 .2 . 6
H az a rdo u s Z o ne Req uir eme nt s
Any forklift truck that is required to be operated in a zone 1 or zone 2 areas must fully comply with and be certified to the Hazardous Zone requirements.
1 2 .3
Op erat i on s
Personnel must not operate forklift trucks unless they comply with the competency standards s t a t e d i n A p p e n d i x 1 o f L i f t i n g E q u i p m e n t M a n a g e m e n t S y s t e m , EP200803208668 a n d a r e specifically authorised to do so. Forklift truck operators shall wear a high visibility vest to aid visibility both while driving and at any time when they leave the operation position. Forklift truck operators must: 1.
Not carry passengers.
2.
Not allow pedestrians to walk under the load.
3.
Not drive in a direction where visibility is blocked.
4.
Not attempt stacking and dismantling stacks on inclines.
5.
Avoid fast accelerating, sharp braking or fast turning.
6.
Be cautious when travelling on slopes, uneven or pot-holed surfaces.
7.
Take care when operating in the vicinity of pedestrians or other vehicles.
8.
Obey traffic regulations
9.
Operators must be aware of hazards in and at the perimeter of their areas of operation.
1 2 .4
C a pa ci t y
Capacities of forklift trucks are rated by the manufacturer and under no circumstances must these capacities be exceeded. The capacity is defined by a given weight with the centre of gravity at a longitudinal distance from the face of the forks. It is stated as a maximum weight at a maximum load centre. A forklift truck with a rated load of 3000kgs at 500mm centres will be able to carry only 2500kgs at 600mm load centres. Rated weight x Rated distance New Distance
=
3000 x 500 600
Page 66 of 247
= 2500kgs
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
13
Mechanical Handling Equipment
1 3 .1
G e nera l R eq ui reme nt s
This section establishes minimum standards for the design and operation of mechanical handling equipment.
1 3 .2
Aer ia l Pla t for m s
This section applies to those platforms, Vehicle Mounted Elevating and Rotating Aerial Devices, Manually Propelled Elevating Aerial Platforms, Boom Supported Elevating Work Platforms, and Self-Propelled Elevating Work Platforms. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-G01 (section 10 page 22)
1 3 .3
D e si g n Cri teri a - Ge nera l
The design, maintenance and operation of this equipment shall comply with an international standard or manufacturer's association rules.
1 3 .3 . 1
I de nti f i ca tio n o f Mob i l e Aer ia l Plat f or m s
The identification and rated load/applicable capacity ratings shall be clearly marked on the mobile aerial platform.
1 3 .3 . 2
Pr e -U se Op era ti o nal Ch e ck s
These inspections shall be performed each day the mobile aerial platform is used and shall include the following: 1.
Check safety devices for malfunction.
2.
Check operating and control mechanisms for proper function.
3.
Inspect for defects such as cracked welds, damaged control cables, and loose cable/wire connections.
4.
Inspect hydraulic or pneumatic systems for observable deterioration or leakage.
5.
Inspect electrical equipment for signs of malfunction, signs of deterioration, and dust and moisture accumulation.
6.
Inspect chains or wire rope for wear or distortion.
7.
Inspect mechanical parts for any signs of wear, cracks, or distortion such as pins, bearings, shafts, gears, couplings, rollers and locking devices.
8. 9.
Hydraulic system for proper oil level. Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage.
10.
Condition and tightness of bolts and other fasteners.
Page 67 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
11.
Legible and proper markings of controls ratings, and instructions.
12.
Legibly and clearly marked with an unique identification number, date of inspection, next inspection date, SWL.
1 3 .3 . 3
O pera ti ona l U se .
Mobile aerial platforms shall be operated according to this section and the manufacturers' recommendations. The following practices shall be followed for mobile aerial platform operations: 1.
Determine that the proposed mobile aerial platform operation is the desired operation after comparing hazards, productivity, and manpower requirements associated with other methods of access.
2.
Before each use, the operator understands the manufacturer's operating instructions and safety rules, has been trained and has read and understood all decals and warnings on the equipment.
3.
Before each use, the operator shall perform a pre-operational check to demonstrate operational readiness, including all limit switches and outrigger drift switches, if applicable, but excluding the tilt alarm/shutoff. If controls do not operate properly the operator is responsible for notifying the PIC. Repairs and adjustments shall be made before operations begin. The operator shall adhere to all decals on the controls.
4.
Personnel must not operate aerial platforms unless they fully comply with the competency standards stated in Appendix 1 of the Lifting Equipment Management S y s t e m EP200803208668.
5.
Before each use, the operator shall survey the area for applicable hazards such as overhead obstructions and high-voltage conductors, debris, bumps and loose obstructions, drop-offs and holes, ditches, soft earth, obstructed path of travel, unstable footing, and other possible hazardous conditions.
6.
Personnel must: a.
Keep all parts of the body, tools, and equipment inside the work platform periphery during raising, lowering, and travelling operations.
b. c.
Hold onto a moving platform using both hands. Consideration must be given to prevailing environmental conditions (e.g., wind, rain, lightning, snow, etc), as well as aspects of the device (e.g., sail area) before commencing operations.
NOTE IT IS A REQUIEMENT THAT ALL ACCESS PLATFORMS WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE. 7.
The operator shall establish appropriate safety zones before initiating operations.
8.
The platform is clearly marked with the number persons it is designed to carry.
9.
The platform shall not be loaded beyond its rated load (capacity).
Page 68 of 247
10.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The operator shall ensure the equipment is within inspection and testing intervals by examination of the periodic re-certification tags and/or documentation.
11.
Operator discipline shall be maintained at all times. Personnel shall keep all parts of the body, tools, and equipment inside the work platform periphery during raising, lowering, and travelling operations.
12.
The use of the mobile aerial platform to move ‘heavy’ materials is not allowed; materials shall not project outside the workbasket.
13.
Fall protection is required at all times for personnel using mobile aerial platforms with a lanyard attached to a dedicated lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.
14.
Tools and other objects shall be carried in canvas bags or by other methods that free both hands and do not present a snagging hazard. Alternate methods of tool delivery beside mobile aerial platforms shall be investigated.
15.
Stow the boom and shut off all power before leaving machine
16.
When two or more persons are on the platform, the operator shall be responsible for all machine operations.
17.
Do not place boom or platform against any structure to steady the platform or to support the structure.
18.
Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach.
19.
When performing welding or metal cutting operations, precautions shall be taken to protect the chassis from direct exposure to weld and metal cutting spatter.
20.
Do not refuel the machine with the engine running.
21.
Free hanging loads shall not be lifted.
22.
The mobile aerial platform shall not be used to exert a sideways force.
23.
Persons younger than 18 years are not allowed in the workbasket.
24.
Outdoor mobile aerial platform operations shall not commence if winds are above 37km/hr steady state or if gusts exceed 46 km/hr or as recommended by the manufacturer. Consideration shall also be given to weather conditions such as lightning, heavy rain etc before commencing operations.
25.
The requirements of this section apply to all uses of mobile aerial platforms; e.g., movement for storage/repositioning and use of the platform close to ground level.
26.
Never allow personnel in the platform while towing, lifting, or hauling, unless so designed.
27.
Never use the boom assembly to enter or leave the platform.
Page 69 of 247
1 3 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ha nd tr ucks
Hand trucks are for moving loads over short distances (typically less than 100m), and are specially designed for lifting and moving packages or pallets e.g. hand pallet trucks. In the latter case the facility to jack up the truck may be incorporated. Hand pallet trucks are suitable for loads up to 3000kg.
1 3 .4 . 1 1.
G e nera l R eq ui reme nt s Hand pallet trucks must be clearly marked with an unique identification number, date of inspection, next inspection date, SWL and have an in-date certificate of inspection from a third party surveyor.
2.
Hand trucks must not be used on sloping steel surfaces such as ramps and particularly not on long inclines (maximum recommended gradient 1:15). If there is no alternative, consideration shall be given to using trucks fitted with brakes.
3.
Hand trucks must not be used on uneven or soft surfaces. Such surfaces, e.g. cracked concrete, distorted tarmac, sand and grassy areas, increase both the physical effort required and the risk of toppling.
4.
Special care must be taken when using hand trucks in split level areas, e.g. loading bays, especially where no guardrails are fitted.
5.
Hand trucks must have all their wheels in contact with the working surface at all times during their use.
Users of hand trucks must report any mechanical defects to the appropriate supervisor.
Page 70 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
14.0 Crane Operation 1 4 .1
I ntr od uc t ion
This section is intended to provide fundamental safe working procedures for crane operators and associated personnel. These basic safe working procedures apply to all crane operations, regardless of crane type or classification. Most crane operations covered in this section can be classified as Routine Operations and as such will be covered by generic Lifting Plans and Risk Assessments (Appendix 3). Where Non-routine crane operations are discussed, Non-routine Lifting Plans and separate Risk Assessment measures are required refer to section 8.
1 4 .2
Reg ula tio n s and Do c ume nt s f or saf e Off sh or e Cra ne Op erat i o n s
The following regulations apply directly to offshore crane operations: 1.
Lifting Operations and Lifting Equipment Regulations (LOLER).
2.
Shell’s global standard on lifting and hoisting EP2005 – 0264-G01 (section 3 page 14).
As necessary, refer to section 8 of this document and the above for guidance when planning any lifting operations. When applicable the requirements of the IMDG Code must also be implemented at the worksite in the form of a risk assessment. Risk assessments/lift plan for ‘Routine’ lifting operations can be ‘generic’ where similar activities are being undertaken in similar places of work. However, these assessments must be reviewed if there is: Reason to believe that the content of the generic ‘assessment or lift plan’ is no longer valid. There is change in the work activity or conditions.
1 4 .3
Li f t in g Team
The number of persons in the lifting team must be determined by the risk assessment/lift plan and be appropriate to ensure the safe operation of the crane at a workplace, especially in relation to minimising the risk of collision between the crane and other plant, and loads contacting other structures, overhead power lines or workers. The risk assessment/ lift plan shall consider the size and complexity of the lifts to be performed when determining the number of operators to work together in the team. Crane lifting operations shall in all instances consist of a team of minimum three people, the crane operator, the rigger/slinger and the banksman. The duties of each are outlined in Para’s. 14.4 to 13.7.
1 4 .4
C ra ne Oper at or
In appointing an individual to the position of crane operator on an Offshore Platform, the crane operator shall have been adequately trained, and has adequate experience and fully complies with the competency requirements of the Lifting Equipment Management System (LEMS) Appendix 1.
Page 71 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The crane operator must be able to undertake all crane operations in a safe and controlled manner. Any crane operator involved in sub-sea lifting operations shall undergo a suitable sub-sea lifting familiarisation programme before commencing operations.
1 4 .4 . 1
C r ane Op era t or’ s R e spo n sib i l it ie s
When a situation arises, or a condition exists, where in the crane operator’s opinion, the safety of personnel, plant or equipment may be jeopardised, he must immediately suspend lifting operations until such time as control measures have been introduced to minimise or eliminate the recognised potential risk(s). When lifting operations have been temporarily suspended due to inclement weather, or in the case of supply vessel back loading/discharging because of the prevailing sea-state, the crane operator must resist any pressure to restart operations until in his opinion it is safe to do so. Operations must not re-commence until the crane operator is fully satisfied that conditions have improved to within the safe operating parameters recommended by the Crane Manufacturer, the MOPO in the platform HSE case. Where no HSE case or MOPO exists the weather limits for platform and rig supply as well as boat to boat lifting activities, shall be 2.5 m swell and a mean wind velocity of 12 m/s.
1 4 .5
Ri gger /Sli nger
The rigger/slinger is the Competent Person responsible for preparing and slinging a load in readiness for a crane lift. He is also responsible for attaching or detaching load slings to and from the crane hook.
1 4 .6
Ba nk sma n
The banksman is the Competent Person with sole responsibility for directing (signalling) the crane operator with respect to movement of the load on the crane hook. The banksman must not however commence load movement signals until the slinger informs him that it is safe to do so.
1 4 .7
Ba nk sma n/S l in ger A ct ivi ti e s
At the commencement of each shift all personnel involved in crane operations will be involved in a Toolbox Talk for all routine lifting operations. The person in charge will make the allocation of duties to achieve an efficient and safe load handling and lifting operation. Banksman duties are as follows: 1.
It is important that the banksman is readily identifiable (by the crane operator) from other personnel e.g. by wearing a high visibility waistcoat. He must also have agreed with the crane operator the method of signalling to be used.
2.
The Banksman controls the initial lifting and movement of the load, and its final positioning on the landing area or site. The banksman will be responsible for load movements only; he will be assisted by a Slinger who will act as the load handler. Additional load handlers can be used as necessary to ensure the safety of the lifting operation.
Page 72 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The Banksman shall not become involved in handling of the load. He must at all times retain an overview of the lifting operation.
4.
The PIC, Banksman and Slinger shall discuss each lifting programme with the crane operator to ensure that each understands the sequence relative to the priority of lifts.
5.
Prior to discharging or back loading of supply vessels, the Banksman shall ensure that both he and the crane operator are in possession of a copy of the cargo manifest. The person in charge must be consulted with regard to the sequence of lifts and positioning of loads
6.
The banksman must be aware of the wind speed and direction and be familiar with the capacities and parameters of the crane in use.
7.
He must check that the deck crew have checked the lifting gear being used for condition, that it is certified for use, is correctly colour coded and is of sufficient capacity to carry out the lift.
8.
Ensure that a cargo-handling pennant of 2 – 3 metres long and correct capacity is attached to the crane hook and is suitable for the particular lift to be carried out. In the case of supply vessel operations, the pennant deployed shall under normal circumstances be a minimum 3m long. Where, because of the crane' s limited boom length, a full-length pennant cannot be deployed, the pennant must be as long as is possible. If no extension is possible, a tag line is to be fixed just above the crane hook. The crane operator and vessel's crew must exercise utmost caution.
9.
Be aware of any obstructions within the crane's radius and working area.
10.
Be aware of potential snagging points in the vicinity of the load whilst hoisting/lowering in restricted areas. Check to ensure that the crane's hoist rope, hook block assembly and attachments have a clear passage.
11. 12.
Ensure that the lifting area is suitably barriered off. If a problem develops whilst lifting or landing a load, the banksman shall identify escape routes for all parties involved with each lifting operation.
13.
If using hand signals, the Banksman shall stand in a position where he can be clearly seen by the crane operator and he can maintain visual contact with the load, load handler(s), and see potential crane boom collision points.
14.
When using radio communications, the banksman shall stand in a position where he can maintain visual contact with the load, load handler(s) and potential crane boom collision points.
15.
When lifting, stop the load just clear of the deck to check balance and security of load. This will also give the crane operator the opportunity to check slippage of his hoist brake. Allowance must be made for the rise and fall of the supply boat in the sea during vessel cargo operations
16.
Make it clear to the crane operator where the load is to be placed.
17.
Warn other personnel in the area of the movement of the load. Do not move the load over personnel.
Page 73 of 247
18.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Keep a check on other activities within the crane's operating area to avoid the development of unforeseen hazards.
19.
When carrying out lifts, under radio communication, which are out of the line of vision of the crane operator (‘blind’ lifts) ensure that the crane operator is at all times aware of the load movement.
20.
During ‘blind’ lifts, the criticality of the lifting operation may be such that there is a requirement for the crane operator to acknowledge and repeat the instruction he has received over the radio.
21.
During ‘blind’ lifts which are being conducted by a hand signalling method and more than one Banksman is being used to relay instructions to the crane operator, each Banksman shall stand in a position where he/she can be clearly seen by the next person in the chain. All signals shall be clear and precise. The Banksman at the load shall have a complete overview of the activity. For vessel cargo operations there must be only one banksman who maintains a clear view of the crane operator throughout.
CAUTION: 22.
WHEN CARRYING OUT BLIND LIFTS, THE USE OF MORE THAN TWO BANKSMEN MAY GIVE AN UNACCEPTABLE SIGNAL TIME DELAY.
When lifting operations are being conducted through hatches to lower decks, always barrier off the hatch area and erect signs with a contact number. The barriers must not be removed until the hatch has been replaced and secured.
23.
If the crane stops, be aware it may well be that the crane operator has lost sight of the banksman's signals. Or, if radio communication is being used, a third party may be transmitted on the working channel. Re-establish visual or oral contact before restarting the lifting operation.
24.
While the crane is engaged in cargo handling operations with a supply vessel, the banksman shall be available to assume control of the operation if requested to do so by the crane operator in the event that he loses sight of the supply vessel deck or an emergency situation arises.
25.
Do not land loads on areas that are designated as ‘No Load’ areas.
26.
Do not direct the crane in a load path over live plant cooler banks etc.
27.
Do not drag trapped slings or other lifting equipment from under loads.
28.
Use lifting equipment specifically designed for that purpose to remove barrels, drums etc. from transit carriers or containers. Always ensure the integrity of the barrel rim. The same equipment shall not be used to lift barrels or drums across platform areas. Secure slinging methods must be used.
29.
Prior to either transfer on the platform or to a supply vessel the security of cargo inside containers or baskets etc must be ensured. Additionally the doors of the containers must be secured by cable tie (tie-wrap) or similar.
30.
Before movement on the platform or to a supply vessel, all units or equipment shall be checked to ensure: a.
Security of panels.
Page 74 of 247
31.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
b.
Security of hatches.
c.
That no loose equipment, tools or debris are lying on roof, framework etc.
d.
That all valves are shut to prevent spillage.
e.
That there are no unavoidable protrusions liable to cause snagging.
Do not use plate clamps for the purpose of transferring steel plate. The use of plate clamps is restricted to situations where plate is being removed from a racking system or is being moved short distances where the lift can be retained just above ground or deck level. A safer more secure method of lifting this type of material e.g. by applying shackles, or by using an appropriate slinging arrangement.
32.
Bundles of tubulars such as drill pipe, casing and scaffold tubes must be slung using the ‘double wrap’ slinging method applied ¼ length of the tubulars in from each end.
33.
Appropriate fist grips and cable ties (tie-wraps) must also be applied to ensure the security of the slinging arrangement.
34.
When guiding equipment, into or out of baskets or containers, to avoid entrapment always keep hands clear of the load. Personnel must not enter baskets or containers during these operations. Fit tag lines to the load.
35.
On occasions when it is necessary to double stack equipment, ensure that the integrity of lifting gear is not jeopardised. Cargo or equipment stowed on top of containers etc must be secured against movement (by wind) or collision with other equipment.
36.
Do not stack cargo carrying units, tanks or equipment, unless they are specifically designed for that purpose and it is permitted by the platform or vessel.
1 4 .8
L oa d C ha rts
Load charts, also called rated capacity charts, identify what a crane is able to lift safely. Load charts must be written in English and/or Bahasa Malaysia and use metric units. Where the crane has one main load chart, this must be fixed in the operator’s cabin in a clearly visible location.
Page 75 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 1 Typical Offshore Pedestal Mounted Crane
1 4 .9
Pr o t oc ol f or t he u se o f tw o-wa y ra di o c om mu ni cat i o ns
Crane operators must always observe the following: 1.
Set up call signs and adhere to them.
2.
Use the agreed call sign at all times to establish the authenticity of commands or directions.
3.
In order to maintain optimum performance and to ensure user safety, if the radio antenna becomes damaged exposing the central core; the antenna must be replaced immediately.
1 4 .10 Tw o-wa y Ra di o C om mu ni ca ti o n s - Ge ner al I nf orma ti on The following must be understood: 1.
The radios must be intrinsically safe and approved for use on SMEP offshore platforms.
2.
The crane operator and Banksman must establish a clear understanding and line of communication prior to the commencement of any lifting operation.
3.
Radio messages must reflect work requirements only; general conversation must not be carried out over the airwaves.
4.
Always ensure that the transmission button is fully depressed before speaking into the microphone.
Page 76 of 247
5.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Speak clearly at all times. Do not release the button until a few seconds after completing your message.
1 4 .10 .1 1.
B an k sman - Ra di o Comm unica ti on
To ensure no radio interference, any banksman’s accompanying assistant(s) radio must be switched off.
2.
When a banksman moves position he must re-establish clear communication with the crane operator.
3.
During 'blind' lifts where the load is being hoisted or lowered for a long time the banksman must: a.
Not keep the transmission button in the depressed position for the duration of the lift.
b.
Not give an instruction at the commencement of the lift and then cease communication until the lift has almost reached its destination.
c.
Give the initial instruction and then talk to the crane operator every 3 – 4 metres to reassure him that the line of communication is still active and that control of the lift is being maintained.
4.
To minimise background noise and distortion ensure that the radio microphone is not exposed to the wind.
5.
Ensure that the radio microphone is not exposed to rain. If a plastic carrying case offering full protection of the radio is not available, place a plastic bag or a piece of cling film around the microphone to ensure it is kept dry.
6.
Do not carry hand-held radios in a coverall pockets. They must be carried in protective holsters attached to the body by either shoulder lanyard or waist belt. In addition to maintaining the integrity of the radio this will also eliminate the danger (to personnel below) of dropping the radio from height.
1 4 .11
Pr e-U se Cra ne I n spe ct i on
1 4 .11 .1
Pr e-r eq ui si te s
On a daily basis, before starting any crane operational activities a crane operator must check: 1.
Crane operational condition, and if any fault conditions have been reported by previous shift by checking the contents of the crane operations log.
2.
By personally speaking to the previous operator before he goes off-shift, about any relevant crane operating observations made that may not be in the log,
3.
For any form of crane maintenance that may be in progress, or is due to start.
4.
If a dedicated banksman is not used, in order to re-establish/establish signalling protocol, with person designated as authorised banksman for the proposed crane operations.
Page 77 of 247
1 4 .11 .2
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
C r ane A c ces s
Each time that the crane operator accesses the crane, to prevent slips, trips or falls, the crane operator must ensure that all access ladders, walkways, gates and hatches are: 1.
Free from obstruction.
2.
Clean and free from oils, greases and solvents.
3.
All deck plates are secured and access hatches are shut.
4.
Service hoses, e.g. diesel, air, and water are empty/de-pressurised and neatly stowed.
5.
Warning signs and barriers are posted as necessary, e.g. Crane Operations Area, Do Not Enter!
6.
No other personnel are present on the crane, in its engine room, or machinery room.
1 4 .11 .3
H ou seke epin g
Keep the crane cab, and machinery spaces in a clean and tidy condition. 1.
Check machinery space is clean and tidy. Clean up any oil spillage and remove any loose materials, e.g. tools, rags. Ensure access routes are unobstructed.
2.
Ensure that all personal belongings or clothing are stored in such a manner that they do not interfere with the controls of the crane during operations. Ensure cab door is unobstructed.
3.
Check that the operator's cabin windows are clean, windscreen wipers and sun visors are in good condition and that the screen wash system is full charged and functions correctly.
1 4 .11 .4
Sa f e ty Eq uipm e nt
The crane operator must carry out daily visual checks to ensure that all safety equipment such as life jacket, emergency escape equipment etc. is secure, to hand and in a serviceable condition. The crane operator (particularly when he is new to the crane) must confirm that the fire extinguishes provided are of the correct type and size as specified by SMEP Shell Petroleum, are within examination certification, and that he knows how to use each of the units provided.
1 4 .1 1 .5
C r a n e P r e - sta r t C he c k s
Carry out the following pre-start checks: 1.
Carry out pre-start checks following the Manufacturer’s checklist. This must include (as a minimum) a check of oil, coolant and fuel. If the crane engine requires refuelling refer to Para 13.11.7. Walk round the crane and the crane access ways, visually checking for any faulty conditions or abnormalities. The checks must include audible warning devices, all safety limits and cut outs, boom, hook blocks, sheaves, wire rope, pendants (including spooling of wire rope on to the drums, rope terminations and any anchorage points), pennants, cab, control levers, slew motors, pinions and brakes.
Page 78 of 247
2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check that the rated capacity indicator is set for it’s correct duty and that the daily test is carried out
3.
If the crane cannot operate, post “DO NOT OPERATE” in a prominent position at the crane’s controls.
4.
Any faulty condition must be reported.
5.
All acceptable conditions shall be recorded.
1 4 .11 .6
Pr e- u se c hec ks f or cran e s n o t i n use f or an e x tended per i od o f ti m e
In cases where a crane is not used for an extended period of time the user shall ensure that the competent person specifies a special programme of pre-use checks and in-service inspections and thorough examination before it is used. The extent and thoroughness of this programme depends not only on the length of the period that the crane was out of use but also on the location of the crane during this period. Crane standing under cover or inside a workshop might require very little extra inspection. Crane that have been out of use in the open and therefore exposed to the weather and atmospheric pollution, etc. might require an extensive appraisal to ensure fitness for work. The programme of pre-use checks and in-service inspections must contain, as a minimum, the following checks. 1.
Any checks that are recommended in the manufacturers instructions for the crane
2.
Checking all ropes for signs of corrosion/degradation and damage and ensuring that there is thorough lubrication.
3.
Checking all control linkage for evidence of seizure or partial seizure and ensuring that there is correct lubrication.
4.
Checking for correct functioning of all the safety devices
5.
Checking hoses, seals or other components for evidence of deterioration.
6.
Checking for corrosion on the structure, access, control linkages etc.
7.
Checking for structural integrity, for example cracks, dents, missing components.
8.
Testing of every motion for several minutes without load, each motion individually at first then by combination of two or more motions simultaneously as appropriate, and then repeating the test with a load.
1 4 .11 .7
C r ane R ef ue ll i ng
When refuelling the crane, crane operators must comply with the following minimum safety requirements: 1.
The crane engine must be stopped. Refuelling must not take place whilst the engine is running.
2.
The appropriate generic COSHH/HRA (Control of Substances Hazardous to Health/ Health Risk Assessment) must be observed prior to commencement of the refuelling operation.
Page 79 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Extreme care must be taken to prevent overflow or spillage of fuel onto the engine, exhaust or electrical equipment.
1 4 .11 .8
Cr ane S ta rt- up
Proceed as follows: 1.
Prior to start-up, ensure that all controls are in neutral position.
2.
Check that all crane emergency stop buttons are correctly reset/set.
3.
Carry out crane manufacturer’s start-up checks.
4.
When the crane power pack starts, check that all air and oil pressure gauges are within manufacturer’s stated safe operating range. Allow engine (power pack) to obtain operating temperature while maintaining a watch on all gauges. Stop crane immediately if any abnormality is observed.
5.
Switch on aviation warning lights.
1 4 .12 C ra ne F unct i o n Te st s 1 4 .12 .1
F un cti on Test Cr ane Control s
Carry out a function check of all crane controls before each lifting operation. If the crane is manned and used continuously, a function test of the crane controls need only be carried out at the start of operations. Carry out safe function tests of hoist, boom and slew systems.
14.12 .2
F uncti on Test Li mit Swi t c h Cut -o uts
Limiting switches are used to prevent physical damage to the crane or part of the crane due to movement of the crane or part of the crane past its designed range of motion. These devices cause braking, including deceleration where appropriate and stopping, when the following extreme permissible positions have been reached: 1.
The highest position of the hook (this is generally known as ‘anti-two block’)
2.
The extreme permissible operating positions of the jib (luff limiter); and
3.
The end positions of horizontally telescoping.
At the commencement of each shift, carry out a function check of the boom minimum radius cutout and the hook block (main and auxiliary) over-hoist cut-outs (anti-two block’). These checks must also include, where fitted, maximum radius and maximum payout limits.
CAUTION:
ALWAYS APPROACH LIMIT CUT-OUTS SLOWLY AND WITH CAUTION SO AS TO LIMIT DYNAMIC SHOCK LOADING AS THE FUNCTION IS STOPPED BY THE CUTOUT, AND TO PREVENT DAMAGE TO CRANE STRUCTURE/EQUIPMENT IF THE CUTOUT FAILS TO OPERATE.
Limit switches must not normally be overridden, but if a cut-out override facility is fitted this too must be function tested.
Page 80 of 247
1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Exercise extreme caution when function testing an 'override' limit switch, See Caution above.
2.
On completion of the override function test, return the override switch to its normal position and move the boom/hook away from the cut-out.
3.
Recheck the cut-out limit switch operation.
1 4 .12 .3
R ated Ca pa ci ty I nd ica tor s R CI ( A utomatic Saf e Loa d I ndicator s A S LI )
Limiting and indicating devices are intended as an aid to crane operators. The devices must not be relied upon to replace the use of the crane’s load chart and operating instructions under any circumstances. Sole reliance on these devices in place of good operating practices may cause an accident. Rated Capacity Indicators, are commonly known as the Automatic Safe Load Indicator (ASLI) and is a vital component in the safe operation of the crane. If during a function test a fault or abnormality is encountered in the operation of the RCI/ASLI, the crane must not be used for lifting until the reported condition has been safely cleared by the crane maintenance personnel. A rated capacity indicator prevents overloading of the crane by stopping all relevant crane functions when an overload is detected. Rated capacity means the maximum load that may be attached and handled by the crane, and may not include the weight of the hook block, falls of rope, slings and rigging hardware. The load to be raised must include the weight of all lifting appliances that are not permanently attached to the crane. The crane’s load chart will provide guidance on any deductions that may need to be made. Prior to the commencement of any lifting operations, ensure that the rated capacity indicator is serviceable. Check as follows that: 1.
The onboard (platform) off-board condition is selected.
2.
The main hoist and auxiliary hoist modes indicate the correct number of falls.
3.
Activate the test function to ensure that all visual and audible alarms operate correctly.
4.
Ensure that appropriate load/radius chart is in good condition and visible from the crane operator’s seat without difficulty.
5.
As a check that the RCI is displaying the correct radius, lower the crane hook over known radius mark(s) (painted on the platform deck).
NOTE
THE OVERLOAD PROTECTION REQUIREMENTS FOR OFFSHORE PEDESTAL AND MOBILE CRANES ARE DOCUMENTED IN APPENDIX 10.
1 4 .12 .4
Eme r gen c y Load Rel ease S ystem
Where fitted, check that the manually operated Emergency Load Release cannot be inadvertently activated during normal operations. A function test of the emergency load release is not part of the crane operator’s routine function checks but is normally tested as part of the third party examination.
Page 81 of 247
1 4 .12 .5
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Eme r gen c y S t op B ut t ons
The emergency stop button shall be used only: 1.
During a periodic function check.
2.
When the normal stop system fails to operate.
3.
In the event of a dangerous engine condition or component failure occurring during crane operations.
1 4 .12 .6
S y stem C hec k s W hi lst Cra ne i s R unni ng
Periodically check all gauges to ensure that all pressures and temperatures remain within the manufacturer’s designated safe operating range. Also: 1.
Listen for unusual engine and/or machinery noises.
2.
Be aware of slight ‘shocks’, which could indicate improper spooling of hoist ropes or imminent equipment/machinery failure.
3.
If anything abnormal occurs: a.
Stop the crane as soon as it is safe to do so, i.e. safely lower any load on the hook.
b.
Check possible cause.
c.
Report defects or malfunctions.
1 4 .13
R ou ti ne Cra ne Oper at io ns
1 4 .13 .1
Si g nal li n g
All platform crane operations require a crane banksman. Crane operators and banksmen must be familiar with the system of signalling used on board the Platform. Banksman signals are illustrated in Appendix 1. With respect to banksman signalling, the following must be strictly adhered to: 1.
The crane operator must ensure that a hand signalling diagram (which complies to the signals illustrated in Appendix 1) is clearly displayed in the crane and is visible from the crane-operating seat without difficulty.
2.
The crane operator must only respond to hand or radio signals given by the authorised banksman. The crane operator must only respond to signals from another person in an emergency situation, i.e. when the 'Emergency Stop' signal is given, either visually or orally.
3.
When hand signals are being used, visual contact with the banksman must be maintained. Crane movements must stop if visual contact is lost and recommence only when a clear line of sight is re-established, or the banksman reverts to radio communication.
Page 82 of 247
4.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
When the crane operator's ability to see the banksman’s hand signals is impaired by inclement weather conditions, darkness, etc., and the lifting operation cannot be executed safely, even with radio communication, crane operations must stop.
5.
When radio communication is used, the crane operator must stop the lifting operation immediately if there is any interruption to the communication (e.g. third party transmission/interference). Crane operations must not restart until clear communication with the Banksman is re-established.
1 4 .14
L oad Ha nd li n g on t he P la tf or m De ck
1 4 .14 .1
R ou ti ne Lif t s
Routine platform lifts will be covered by a generic risk assessment and lifting plan and can be undertaken without further procedures being required. (Refer section 8)
1 4 .14 .2
N on -r o uti ne Li f t s
For a non-routine lift, a specific risk assessment and lift plan (specially generated by persons with related competence) will be required. A non-routine lift must not be undertaken until these documents are in place. (Refer section 8)
1 4 .14 .3
P lat for m De ck W or k
Before starting lifting operations, the crane operator must assess the prevailing weather conditions, e.g. wind speed/direction and visibility. Lifting operations must not commence if environmental conditions are liable to jeopardise the safety of the activity. The crane must not be operated in wind speeds above the limit set by the manufacturer and/or the MOPO in the platform safety case. The following instructions with respect to load movements on the platform deck must be observed and understood: 1.
While there is a shared responsibility for the safety of each lifting operation (e.g. crane operator, banksman and rigger or slinger) the banksman is in control of load lifting and manoeuvring activities.
2.
The work area must be closed off with barriers to prevent unauthorised personnel from entering the work area. The barriers may be made from red/white marking tape.
3.
To facilitate safe handling of the load attach tag lines or handling lines to all long or awkward lifts, e.g. casing/drill pipe bundles, completion baskets, etc. Ensure that the tag lines are secured to the load and not to the rigging gear.
4.
If the load is hazardous check that it is segregated from other loads and that it has clear markings indicating its hazardous contents.
5.
Before a load is attached to the crane hook the crane operator must be aware of the weight of the load and its distance (radius) from the crane, and ensure that the RCI is set to the correct duty. The crane operator must also be confident that he has the knowledge and experience to carry out the lift.
Page 83 of 247
6.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ensure that a cargo-handling pennant of 2 – 3 metres long and of the correct capacity (refer to Para 14.42) is attached to the crane hook and is suitable for the particular lift to be carried out. Where because of the crane' s limited boom length a full-length pennant cannot be deployed, the pennant must be as long as is possible. (see fig 79)
7.
Pennant’s when used to lift pre-slung loads shall be hooked directly to the master link of the sling set attached to the load. i.e. no sling shall be attached between the pennant hook and the master link. In general, rigging shall be kept to a minimum, except where required to allow connection from a deck load, in order to reduce the number of “links” between the load and the pennant hook.
8.
The crane operator must check with the rigger/banksman that the lifting gear is correctly colour coded, of sufficient capacity and is correctly secured and positioned on the load, i.e. over the centre of gravity so as to give a stable lift.
9.
Check that there are no loose tools, equipment, etc on the load.
10
Keep the load within the specified radius of the crane. Do not permit load handlers to push or pull loads, or the crane hook, to outside the working parameters of the crane. The crane hoist rope, from boom tip to crane hook, must be vertical before a lift is started.
11.
At the commencement of the first lift, the crane operator must carefully check the operation of the hoist brake to ensure no slippage.
12
Without the prior consent of the OIM, or their delegate, loads must not be moved over: a.
Unprotected accommodation or offices.
b.
Vulnerable plant, machinery, live gas lines or similar wireline and coil tubing operations.
NOTE: WHERE A LOAD CANNOT BE MOVED OTHER THAN OVER WORKSHOPS, OFFICES OR SIMILAR ACCOMMODATION, PERSONNEL MUST BE TEMPORARILY EVACUATED FROM DANGER AREAS IN THE PATH OF THE LIFT. 13.
Before hoisting, check that all personnel are clear of the area of the load and load path. When lifting equipment from baskets or containers a lift shall not start until all personnel are clear of the immediate area of the lift, i.e. outside of, and clear of the basket or container.
14.
Take up sling slack to confirm that the banksman/rigger has correctly positioned the crane hook centrally over the load lifting point, adjust hook position as necessary to minimise any 'drift' of the load as it is lifted clear of the deck.
15.
As the load is lifted off the deck, monitor the rated capacity indicator for possible overload situation.
16.
During crane operations, carry out all movements in a controlled manner. Smooth operation of the crane reduces the possibility of the inherent risks involved with undue shock loading or stress to the structure and/or machinery.
17.
When moving loads across the platform deck, the crane operator shall be aware of any other activities/obstructions within the crane radius arc.
Page 84 of 247
18.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
When carrying out ‘blind lifts’, monitor the RCI for any loss or increase in the weight of the load, which could be an indication that the load, or the load slings, have snagged on the superstructure or on adjacent equipment. If this occurs, stop the lifting operation immediately and advise the banksman.
19.
The crane operator must not leave the crane controls whilst there is a load on the
hook. 20.
If weather conditions become adverse during a lifting operation, the crane operator must resist pressure to carry out lifts, which have now become dangerous. Suspend lifting operations until conditions improve and the lifting operation can be carried out safely.
CAUTION:
NEVER WORK OR WALK UNDER A HOISTED OR SUSPENDED LOAD UNLESS IT HAS BEEN ADEQUATELY SUPPORTED FROM BELOW AND ALL CONDITIONS HAVE BEEN APPROVED BY THE PIC.
1 4 .15 Car go ha ndli ng - sup pl y v e ssel w ork 1 4 .15 .1
R ou ti ne Lif t s
Routine vessel cargo lifts will be covered by a generic risk assessment and lift plan.
1 4 .15 .2
N on -r o uti ne Li f t s
For a non-routine vessel cargo lift, a separate risk assessment and lift plan (specially generated by persons with related competence) will be required (See Section 8). A non-routine vessel lift must not be undertaken until these documents are in place.
1 4 .15 .3
Ve sse l Cargo Ha ndling Oper ati ons
When carrying out vessel cargo handling work, the following must be observed: 1.
Establish early radio communication with the vessel Master or where applicable the vessel's deck crew. Obtain a copy of the cargo manifest(s), prior to commencement of the operation to be aware of the weights of the cargo to be discharged/back loaded to/from the vessel.
2.
Check load weights to see if any loads are positioned outside crane load/radius operating limits.
3.
If a load is hazardous, check that it is segregated from other loads in accordance with the IMO (International Maritime Organisation) IMDG Code (International Maritime Dangerous Goods Code), and that it has clear markings indicating its hazardous contents and that appropriate paper work forwarded to or from the vessel, in advance.
4.
Ensure that the pennant length provides an adequate safety margin for the sea state; i.e. the pennant must be appreciably longer than the maximum wave height. Ensure that the pennant is of the correct capacity. (refer to Para14.42)
5.
Prior to the commencement of cargo handling from/to the vessel, confirm the prevailing wind and sea-state conditions. If conditions are marginal, for whatever reason e.g. weight, position or sea state, discuss proposed operation with Vessel Master, and the Person in Charge (PIC). If there are any doubts, the proposed cargo
Page 85 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
transfer must be postponed until conditions improve. No cargo operations are to commence until the vessel's master verbally confirms by radio that he is satisfied with the conditions and his ability to maintain station and that the required controls such as communications are in place. 6.
Before hoisting loads from the vessel deck, ensure that the ship's crew have reached a position of safety well clear of the cargo handling area and have given the appropriate hand signal, or verbal instruction, to hoist. Similarly when back loading cargo to a vessel deck, ensure that the ship's deck crew are in a position of safety, well clear of the intended cargo stowage area.
7.
When lowering loads to a vessel deck, ensure enough slack is given in the pendant and slings to allow for the movement of the vessel.
When hoisting loads from a moving vessel deck packed with cargo, the crane operator shall be alert for:
8. 9.
a.
‘Snag-ups’ with adjacent cargo.
b.
Loads, which may still be secured to the vessel deck.
c.
Cargo that is heavier than the manifested weight.
Whenever possible, hoist/lower loads over open water and not over the vessel deck. While engaged in vessel activities, avoid excessive impacts and avert any shock loading being transmitted to the crane. Wait for the correct moment to make the lift, do not be rushed by signals from the vessel deck crew.
10
Where practicable, do not use maximum boom radius (for the load) during vessel cargo lifts. Keep some boom radius (within RCI limits for weight of load) in reserve, to compensate for vessel ‘drift’ movement, and if the vessel is unable to hold station, abort action.
11.
If a load is immersed in the sea for any reason, be aware of the probable increase in weight from water retention. Report the incident to the Person in Charge (PIC) for Lifting Operations so that he can check the load and/or contents for any damage sustained following its retrieval.
12.
When moving long tubulars, baskets or other awkward loads, before taking the lift ensure that tag lines are attached to assist control and handling of the load on the platform/vessel deck. Check that tag lines are secured to the load and not the load rigging.
1 4 .16 Tr an sp ort of sca ff old i ng Ma teri al s a nd Boa rds Scaffolding material and boards shall be transported in dedicated load carriers.
NOTE: FOR ALL OFFSHORE LIFTING OPERATIONS SHACKLES SHALL BE OF THE 4 PART BOW SAFETY-ANCHOR TYPE, WITH RETAINING NUT AND SPLIT PIN. SCREW PIN SHACKLES SHALL NOT BE USED.
Page 86 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 2
Beware of Swinging Hooks
1 4 .17 Ge ner al Op era ti ng In s tr uc t i ons This section covers those areas of safe operating not specifically covered previously: 1.
Do not engage slew parking brake or lock until the crane superstructure has come to a complete halt.
2.
Do not authorise access to the crane or its superstructure until the crane has been brought to a complete halt and the parking brake applied.
3.
Do not use limit switches or cut-outs to stop the crane boom or load line motions.
4.
Do not use the crane to drag (fish) loads.
5.
Do not carry out single point lifts with one handling pennant hooked into the other. This presents snagging potential.
6.
Do not, on cranes equipped with more than one hook block, operate the crane with a handling pennant or other ancillary equipment attached to the stowed hook block.
7.
Except when back loading to vessels, do not lift long or awkward loads without tag lines attached to the load (not the slings).
8.
Do not interfere/tamper with rated capacity indicators or other safety equipment attached to the crane, such actions are extremely dangerous.
9.
Never allow personnel to ride on crane hook blocks or on loads.
10.
Never slew loads over or near diving operations.
11.
Do not lift loads of large surface areas, e.g. steel plates, in high wind conditions. Always assess the effect the weather conditions could have on the behaviour of the load.
12.
Do not lift wire ropes, cables, or other material/equipment of a similar nature, which are not already spooled on drums provided for that purpose. An appropriate Risk Assessment must be conducted and one of the following methods adopted:
Page 87 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
a.
Coil and then securely sling the material using an approved slinging arrangement method involving at least a double wrap and bite.
b.
Lift the material in a single strand, provided that:
c.
The lifting arrangement is secured approximately quarter to one-third distance from one end by the use of a clamp or other device to prevent the lifting sling slipping.
d. 13.
A certified lifting device specifically designed for the purpose is used.
When carrying out lifts from areas such as the Drill Floor etc, ensure that the Banksman is correctly positioned to determine the crane boom proximity to potential collision points
14.
Ensure that, where necessary, a Banksman assists the stowing of the boom in its cradle.
15.
Exercise caution when lowering a ‘light’ hook block so that the winch rope ‘payout rate’ is not exceeded.
16.
Ensure awareness of the operation of the crane emergency load release and load lowering equipment (if fitted).
17.
When operating from a moving vessel, the crane operator must assess his abilities to correct a swinging cargo and stop operations.
1 4 .17 .1
S ta bi li s e t he L ift
Ensure that at all stages of the lifting operation, the load remains in a stable condition. In general, the load may become unstable if at any time the centre of gravity of the load is not vertically beneath the crane hook or the centre of gravity of the load is higher than the point of attachment of the slings to the load or if the contents can move around (i.e. liquids in half full tanks).
1 4 .17 .2
T ri al Lif t ing
With all lifting operations the load shall only be lifted a nominal distance in the first instance. This trial lift allows the operator to check the load weight, balance stability and security whilst it is in a relatively safe position. If any discrepancies are found the load can be lowered and the slinging revised. The sequence of the trial lift and adjustments shall be repeated until the crane operator is satisfied that the load is safe to lift. Allowance must be made for the rise and fall of the vessel when making the trial lift offshore.
Page 88 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
15.0 Sub-sea Lifting and hoisting operations The processes and practices in this section do not apply to any other operations or contractors not involved in the sub-sea operation. The operations described will normally be conducted from Dive Support Vessels (DSV), Well servicing vessels, Multi support Vessel, which includes ROV, Diving and construction operations. Some cranes are suitable for sub-sea lifting, however not all. The crane manufacturer must be contacted for written confirmation of the crane’s suitability for sub-sea lifting before the crane is used. Normally sub-sea rated cranes have a wire rope constant tensioner or a passive/active heave compensator system installed, any other crane sub-sea systems must not be used without the express, written approval of SMEP's Lifting Technical Authority. Typical operations may include; •
Offshore installation, recovery, maintenance and repair of sub-sea equipment;
•
Lifting in connection with diving or ROV operations;
1 5 .1
Compet en ce
The standards of competence required for the key roles in planning, managing and executing sub-sea lifts are to be in compliance with this document. The contractor will demonstrate compliance for the entire crew and divers who are involved in the lifting and hoisting operations, prior to mobilisation.
1 5 .2
Ca teg or i sat i on of Lift s
All sub-sea lifting operations will be classified as complex refer to Section 8.8.5.
1 5 .3
Li ft P lan ni ng
All Sub-sea lifts will be executed to a written lift plan as detailed in Section 8.8.5.
15.4
Management of Change
The contractor’s process for management of change will have been reviewed and any issues resolved prior to mobilisation. When it is recognised that a change is required to a lifting operation that exceeds the contingencies included in the plan the contractor’s management of change process will be applied. It is important that contingencies are built into lift plans to minimise the possibility of disruption offshore which may make the safe execution of the lift more difficult.
1 5 .5
S ub - sea li fti ng ru l e s & s ub - sea cla ri fica ti o n s
The following practices are ‘deemed to comply’ practices for sub-sea activities only. Lifting operations will be undertaken by a minimum of four competent people: crane operator, banksman and two riggers. At Sea Back-deck operations Deck foreman is the banksman and controls access to the back deck. Typically two riggers will support him on the deck. Other persons are the crane operator and the PIC.
Page 89 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The minimum manning and competence levels will be maintained as crew are rotated for breaks etc. Hand over procedures must be in place. Lifting Sub-sea involving divers Dive supervisor acts as the banksman and gives instructions to the crane operator. The designated diver gives instructions to the supervisor to move the load. Either or both divers can be load handlers. ROV Launch and Recovery Provided that the person operating the launch controls has direct line of sight of the load handler and effective communication by speech or radio and there are no other operations that may conflict and the risk assessment supports two man operation then launch and recovery of the ROV may be done by two people. The banksman controls the initial lifting of the load, lay-down of the load and lifts that are out of the line of vision of the crane operator. The lift supervisor or PIC is responsible while a load is in the air. Lifting Sub-sea involving Divers with or with out ROV Dive supervisor acts as the banksman and gives instructions to the crane operator. The designated diver gives instructions to the supervisor to move the load. If both ROV and divers are in the water, the coordination is done through the dive supervisor.
1 5 .6
L oad Ha nd li n g
The banksman must: ensure that he/she is easily identifiable by wearing a high-vis waistcoat, which is clearly marked to indicate that he/she is the banksman. When the banksman controls the lift remotely using communication equipment and is out of sight of the working party he does not need to wear high visibility clothing. For example lifts controlled by the Dive Supervisor. When control is passed between several banksmen there will be a clear handover procedure agreed before the lift starts. This is to be confirmed at the toolbox talk.
1 5 .7
Compet en ce of Per sonn el
Sub-Sea contractors will demonstrate that they have a robust system of competence assurance and refresher training for all personnel involved in lifting.
1 5 .8
Load Charts
Sub-sea capacity charts must be posted in the operators cabin and the rated capacity indicator must be programmed for sub-sea duties.
1 5 .9
Cr ane Mai nte na nce
The crane maintenance during sub-sea operations will be inline with the crane manufacturers recommendations.
Page 90 of 247
1 5 .10
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
R op e Mai nt e na n ce
Spin resistant multistrand ropes have a characteristic of developing large numbers of internal wire breaks, long before external signs of deterioration become apparent. This characteristic becomes even more pronounced when the rope is frequently immersed or sprayed with sea water, as this leads to severe internal fretting wear. 1.
All sheaves and guide rollers in contact with the moving rope must be given regular visual checks for surface wear, and lubricated to make sure that they run freely. This operation must be carried out at appropriate intervals (generally not exceeding more than one week during sub sea operations).
2.
The rope must be maintained in a well lubricated condition using appropriate marine grade rope lubricants (as recommended by the rope manufacturer). The maintenance of internal lubricant is especially important for multistrand ropes, due to the way they are constructed.
3.
A surface dressing must be applied at appropriate intervals from the winch drum to the hook, commensurate with the depth to which the hook is to be deployed during sub-sea lifting operations. Application of the surface dressing may be by whatever application method is convenient.
4.
In order to make sure that the inner layers of the rope remain well lubricated, use an effective pressure lubricator, an effective lubricator is one that will not only convey fresh lubricant to the core of the rope but will also displace trapped water. This generally requires high pressure application of a heavy grade of lubricant, from the winch drum to the hook, commensurate with the depth to which the hook will be deployed. This shall be carried out at intervals not exceeding six months. The lubricant must be an appropriate heavy marine grade, as recommended by the manufacturer of the lubricator, and approved by the rope manufacturer.
1 5 .11
C r ane I n sp e cti o n
The routine crane inspection during sub-sea lifting operations must be inline with the crane manufacturers recommendations.
1 5 .12
R op e I n sp ec ti o n
During sub-sea lifting operations all accessible rope and associated equipment shall be checked visually each day. Particular attention to the end termination and the part of the rope entering the end termination. A visual inspection of the rope, from the winch drum to the hook commensurate with the depth to which the hook will be deployed, must be carried out at weekly intervals during sub-sea lifting operations. At the same time, because multistrand rope tend to suffer internal damage, local reductions in diameter or lay distortions shall be treated with the utmost suspicion as they are likely to indicate serious internal degradation. Any anomalies shall be reported immediately and lifting operations stopped. At intervals not exceeding 12 months, the rope shall be replaced.
Page 91 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
When a rope is not in service, corrosion can take place, particularly within the rope where sea water may have been trapped by any external dressing. This means it is necessary to subject the rope to appropriate inspection and tests, before putting it back into service. For crane ropes not in use, when the period of non-use exceeds one month, the wire rope and termination shall be subjected to external visual inspection to identify any corrosion or damage over the entire length of rope, including the end termination.
1 5 .13
Cr ane /Rope R e cor ds
Full records shall be kept for the crane involved in sub-sea lifting operations. This crane record, shall be part of the records of the crane’s planned maintenance programme, the records shall contain details of all daily, weekly inspections and maintenance carried out on the crane. Full records shall be kept for each rope involved in sub-sea lifting operations, from its first installation to discard. The records shall contain the following information: 1.
At installation, details of the installed rope must include: a.
Date, length installed and name of rope manufacturer.
b.
Minimum breaking load and certificated test strength.
c.
Diameter, construction, wire grade and surface treatment.
2.
Confirmation of daily and weekly inspections.
3.
A record of lubrication (date, lubricant used and application method).
4.
A record of inspections, maintenance and testing, needs to include: a.
Results of six monthly inspection.
b.
Details of any length removed.
c.
Details of the NDT, if applicable;
d.
Details of pressure lubrication, if applicable;
e.
Details of re-termination;
f.
Results of the functional tests.
Page 92 of 247
16
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Mobile Crane Operations
Only crane operators who have been adequately trained, and has adequate experience and fully complies with the competency requirements of the Lifting Equipment Management System ( EP200803208668) a r e a l l o w e d t o o p e r a t e c r a n e s .
1 6 .1
D oc u me nt s
The following documents must be present on mobile cranes: 1.
Crane manual.
2.
The current certificate of examination.
3.
The safe working load charts in English or Bahasa Malay.
4.
Crane operators daily inspection log book.
5.
Registration document.
6.
The current certificate of examination for all lifting equipment belonging to the crane.
7.
Mill certificates for all ropes fitted to the crane.
8.
MPI reports of the Hooks / Hook blocks.
9.
Maintenance records.
1 6 .2
Load Charts
Where the crane has numerous load charts (e.g. for different boom and fly jib configurations), the charts must be kept in a book, folder or envelope in the operator’s cabin. Lifting must not take place unless the load charts are in the crane cabin. Although the crane’s load capacity indictor system may appear to be operating correctly, the load charts must be available to verify that the crane is not being overloaded. The lifting capacities specified on a load chart must never be exceeded, except during testing of the crane by the third party surveyor under controlled conditions. The lifting capacity of a crane is limited by: 1.
Structural strength when the working radius is small; and
2.
Stability when the working radius is greater
The load charts on most cranes have a bold line or shaded area dividing the chart into two segments. The divided segments show the crane operator, which capacities are, limited by structural strength, and which are limited by stability. Ratings above the bold line are based on structural strength, while the ratings below the bold line are based on the stability of the crane. If a crane is overloaded in the structural area of the load chart, a structural or mechanical component of the crane may fail. However, if the crane is overloaded in the stability area of the load chart, the crane may overturn. On some mobile cranes, there may be numerous load charts for differing boom and counterweight configurations. The load charts may be complex and include numerous conditions that must be complied with to ensure the crane can safely lift a load. Two important factors that are often overlooked when reading load charts are:
Page 93 of 247
1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The need to subtract the mass of the hook block and lifting slings from the gross capacity of the crane at the particular radius, unless otherwise noted on the load chart. For example, if the load chart states the crane can lift 20 tonnes at a given radius, but the hook and lifting gear have a combined mass of one tonne, the load to be lifted cannot be greater than 19 tonnes. This issue becomes critical for heavier hook blocks and lifting gear (e.g. spreader beams).
2.
The need to subtract the mass of the fly jib from the capacity of the main hook when lifting from the main hook on the main boom with a fly jib attached to the boom head, unless this is allowed for and noted on the load chart. Capacities of the main boom are generally based on the fly jib being removed.
If this issue is ignored, the likelihood of the crane overturning can be very high.
1 6 .3 1.
Si t ti ng o f Cra ne s The ground or foundation, temporary supporting structures, packing or anchor points must be of sufficient strength and stability for the maximum loading to be imposed.
2.
Settlement and deflection of ground support or structures must also be taken into account.
3.
Cranes must not be sited on soft or waterlogged ground unless adequate precautions have been taken to provide support to each wheel/outrigger.
4.
Dynamic loads, which might arise during operations must be estimated and calculations must include a 25% margin to allow for unpredictable effects.
5.
Mobile crane’s shall not be used during wind conditions above 15 m/s or above the crane supplier’s recommendations, whichever is the lower. A wind anemometer shall be fitted to the boom tip alternatively a hand-held anemometer can be used in the area of the lift.
6.
Sitting of cranes on sloping ground must be avoided. Where necessary the crane shall be levelled using outriggers or other means to give a level and stable working platform.
7.
Mobile cranes must be positioned so that the risk of injury from collision with other plant is minimised. This issue is particularly important where mobile cranes are set up on public roads. Another way to minimise the risk of injury from collision with other mobile plant and vehicles is to increase the visibility of mobile cranes. One way to increase the visibility of a crane is to permanently mark the crane’s outriggers with high visibility hazard striping (i.e. ‘zebra striping’). The outrigger beams and/or hydraulic cylinders shall be marked with the hazard striping. The striping must:
8.
a.
Be at an angle 30-60 degrees to the horizontal;
b.
Be 40-150 mm wide; and
c.
Consist of two contrasting colours, black and yellow.
For cranes sited in flowing water careful investigation must be made of any potential for scouring effect. Constant checks must be made during operations to monitor the
Page 94 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
situation. The possibility of cranes being trapped by rising water must not be overlooked and cranes must be moved to safe position as necessary. 9.
Checks must be made to ensure that cranes are not sited above or adjacent to excavations or inadequately compacted ground, which are be liable to subside.
10
Particular care must be taken when cranes are sited in the proximity of hazards including other cranes.
11.
Prior to the commencement of any lifting operations, the temporary closure of roads and access required for crane operations must be notified to all parties likely to be affected by the closures.
12.
Cranes must not be operated unless all personnel including third parties and members of the public are cleared from the radius of the crane’s boom and loads with a safety margin of 5 metres. The barriers may be made from red/white marking tape.
13.
The operation of any crane within 15 metres height or reach from the nearest point of contact (typically the boom, jib or cab) with live overhead electric cables or conductors is strictly prohibited.
14.
Mobile cranes must not be operated where the operating radius of the boom overlaps with that of another crane unless: a.
There is a clear over-riding business requirement and
b.
There is no alternative sitting or equipment that can be used and
c.
The operators and banksmen of both cranes are supervised by a single supervisor in accordance with the written lift plan.
15.
Where there is a danger of any part of the crane fouling any overhead or nearby obstruction e.g. bridges, gantries, pipe work, scaffolding, buildings or walls, the operator must work only under the direction of a banksman so positioned as to have a clear view of the crane and the obstruction.
16
Adequate clearance must be allowed between any part of a crane and the nearest obstruction to prevent contact with, and/or the trapping of personnel when the crane is slewed.
17.
Where it is not possible to allow such a clearance, no access must be allowed whilst lifting operations are in progress.
1 6 .4 1.
Pr ep ar ati on Preparations for lifting operations must be in accordance with manufacturers recommendations and the lift plan.
2.
Load indicators, overload cut-outs, limit switches and all other safety devices must be function tested before operation of a crane.
3.
Visual load/radius indicators and rated capacity indicators must be checked after assembly, boom length change or any other factor, which might affect correct and safe operation.
Page 95 of 247
4.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Outriggers must be fully extended properly supported and if required by manufacturers pinned in position.
5.
Jacks and outriggers must be correctly fitted with feet to provide a firm base for the crane. Prior to operations, the crane must be jacked in accordance with manufacturer's recommendations.
6.
Counterweights of the correct weight must be correctly fitted prior to operation. Additional counter-weighting must be fitted as necessary to suit load requirements and any boom or jib extension.
7.
On wheeled cranes with pneumatic tyres particular care must be taken to ensure tyres are inflated to correct pressures as recommended by the crane manufacturers.
8.
Ensure that a pennant of 2 – 3 metres long and correct capacity (refer to Para14.43) is attached to the crane hook and is suitable for the particular lift to be carried out. Where because of the crane' s limited boom length a full-length pennant cannot be deployed, the pennant must be as long as is possible.
C AU T I O N : N E V E R W O R K O R W AL K U N D E R A H O I S T E D O R S U S P E N D E D L O AD U N L E S S I T H AS B E E N AD E Q U AT E L Y S U P P O RT E D F R O M B E L O W AN D AL L C O N D I T I O N S H AV E B E E N AP P R O V E D B Y T H E P I C .
NOTE: IT IS A REQUIREMENT THAT ALL MOBILE CRANES WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE.
1 6 .5
Li f t P l an s
All crane operation shall be suitably planned as described in Section 8 Before lifting operations, the person in charge (PIC) of the lift must ensure: 1.
The load is robust and not likely to break up, deform or become damaged during the lifting operation.
2.
The load is properly slung and evenly balanced using certified loose lifting tackle with a SWL, adequate for the operation
3.
The lifting gear is properly attached to the load and where lifting points are used they are designed for that lifting operation and are in good condition with appropriate certification stating the WLL and conditions.
1 6 .6
E nvi ronm e nta l Cond itions
Cranes must not be operated if the visibility of the crane operator or the banksman is significantly impaired by heavy rain, haze etc. Lifting operations must be suspended during heavy rain, except where it would be more hazardous not continuing the lift. Cranes must not be operated in darkness without adequate lighting to illuminate the crane’s lifting area.
Page 96 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Wind imposes additional stresses on both the crane and its loads, particularly when a load starts to swing. Extreme caution must be used during windy conditions and the following restrictions must apply: 1.
Lifting of bulky objects with large surface areas (tubulars, pipes, shipping containers, steel plates etc.) must be stopped when the wind speed reaches or exceeds 13m/s.
2.
All lifting operations must stop when the wind speed exceeds 20.5 m/s.
1 6 .7
G e nera l O per ati ng I ns t r uc ti on s
Cranes must not be left unattended whilst suspending a load. When not in use and left unattended, crane cabs and control compartments must be kept closed with controls or power packs locked off. Cabs and control compartments must be locked and the vehicle parked without obstructing normal access. Cranes must not be used for any purpose other than for lifting in a vertical plane. Do not use for dragging or fishing a load. Crane booms must not be used to apply sideways force to an object. For example, during demolition, tree felling or pushing materials and boxes. Cranes must not be used as winches to drag materials or equipment. Cranes must not be used if they are not fully rigged or are in a defective condition, e.g. if outriggers do not fully extend, there are hydraulic fluid leaks or controls and safety equipment are defective. Lifting operations must be conducted cautiously without hoisting, lowering or slewing at excessive speed. Load swinging and snatch loading must be avoided. On completion of crane operations, the crane boom and hook must be properly secured before the crane operator leaves the crane. The crane boom must be left on any fitted rest, with the hoist rope slackened, or pointing downwind with the boom angle lower than 45°. Any defect or damage to the crane or its structure affecting the safety of the crane must be reported. The crane must be taken out of service immediately the defect or damage is detected and not used until it has been rectified, and re-certified if necessary.
Page 97 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
17.0 Multiple Crane Lifts Lifting a load with two or more cranes requires greater attention to planning and supervision, because the effects of the relative motion between the cranes may create additional loadings on the cranes, the load and the lifting gear in place.
1 7 .1
S a f e t y Mea s u r e s f or Mu l ti p l e Cra n e Lif t s
Where possible, avoid hoisting a load with more than one crane. However, where it is necessary to lift a load using more than one crane, the following steps must be taken: 1.
The person in charge (PIC) of the lift shall be in overall control of the lift.
2.
Make an accurate assessment of:
3.
a.
The share of the load that is to be carried by each crane.
b.
How the load sharing is to be proportioned.
c.
How the proportioning is to be maintained.
Make sure the instructions to each crane operator and other persons involved are clear, and rehearse the operation wherever possible.
4.
Use cranes of equal capacity and similar characteristics, where practicable.
5.
Make sure that both cranes are aligned in the same direction when using non-slewing type cranes in the pick-and-carry mode.
6.
1 7 .2
Use luffing up in preference to luffing down.
Ca lculated S hare of t he Loa d
Where multiple hoisting operations are carried out, the following minimum capacity requirements for each crane will apply: 1.
For two cranes—20% greater than the calculated share of the load.
2.
For three cranes—33% greater than the calculated share of the load.
3.
For four or more cranes— 50% greater than the calculated share of the load.
If it is not possible to comply with the minimum capacity requirements stated above, then an engineer must check and certify the lifting plan.
1 7 .3
Pri n ci ple s fo r Mu ltip l e C ra ne Lift i ng
The following factors are to be considered when planning for multiple crane lifts: 1.
Mass of the load.
2.
Position of the centre of gravity.
3.
Mass of the lifting gear.
4.
Safe working capacity of the lifting gear.
5.
Synchronisation of crane motions.
Page 98 of 247
1 7 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
M a s s of t he L oa d
Ensure the total mass of the load and its distribution is either known or calculated. Where the information is taken from a technical drawing, ensure allowances are made for manufacturing tolerances.
1 7 .5
P o si ti on of t he Ce nt re o f Gra vit y
Due to the variable effect of manufacturing tolerances and rolling margins, the position of the centre of gravity may not be accurately known. Accordingly, the proportion of the load being carried by each crane may therefore be uncertain.
1 7 .6
Ma ss of t he L if ti n g Gea r
Ensure the mass of the lifting gear and its distribution are accurately known and included as part of the calculated load on the cranes. Where heavy or awkwardly shaped loads are handled, the deduction from the safe working loads of the cranes to allow for the weight of the lifting gear may be quite significant.
1 7 .7
Safe W orkin g Cap aci ty of the Lif tin g Gea r
Ensure the distribution of the forces within the lifting gear, which will arise during the lifting operation, is established. The lifting gear must have a safe working capacity margin in excess of that needed for its proportioned load. Determine whether special lifting gear is required to suit the maximum variation in distribution and direction of applied loads and forces, which may occur during multiple lifting.
1 7 .8
S yn chr oni sa ti on of Cra ne Moti ons
Minimise the variation in the direction and magnitude of forces acting on the cranes by synchronising the cranes’ motions. Where possible, ensure cranes of equal capacity and similar operating characteristics are used. However, in practice, there will always be some variation due to differences in response to the activation of the motion controller and the setting and efficiency of the braking system. As it is unlikely that the motions of the cranes will be accurately synchronised, ensure that an assessment of the effect of variation in plumb of the hoist ropes, which may arise from inequalities of speed, and the means for keeping such inequalities to a minimum, is made. To allow for these inequalities, the lifting operation must be performed at low speeds with extreme care to ensure the hoist ropes are kept as close as possible to vertical. The rated capacity of a crane is calculated on the assumption that the load will be raised and lowered in a vertical plane. The crane boom has limited strength in the lateral plane.
Page 99 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
18.0 Precautions when Using Mobile Cranes 1 8 .1
La tti ce Bo om Cra ne s
On lattice boom cranes, the top of the extended boom must not be lowered to a point below the horizontal line that passes through its boom heel pivot pin. If the boom tips below this plane, the angle of pull of the boom luffing ropes could cause the boom to buckle before the boom begins to lift. Lattice boom cranes must not be moved uphill with an unloaded boom in the near vertical position, or operated: 1.
With the boom at an angle less than that shown on the load chart.
2.
With the boom hard against the boom backstop to avoid serious damage to the structural members of the boom. Regard the boom backstop as a safety device only.
1 8 .2
H yd ra ul i c Bo om Cra nes
When extending the boom on hydraulically operated cranes, ensure that the boom sections are extended or retracted in accordance with the manufacturer’s recommendations. The crane must not be operated with the boom at an angle less than that shown in the load chart.
1 8 .3
Pr e ca ut i o n s wi t h Pi ck -a n d - Ca r r y C r a n e s
When moving a load in the pick-and-carry mode, the banksman must remain in sight of the crane operator, and not walk in the path of the crane. When travelling and manoeuvring with a load, the crane operator must ensure that: 1. 2.
The slew brake is applied at all times other than when the slew motion is being used. Precautions are taken on uneven road surfaces when loaded or unloaded, as an undulation in the road surface may move the crane into an unstable zone.
3.
The slewing brake or lock is applied when travelling with a load.
4.
The crane is not moved uphill with an unloaded boom in the near vertical position.
Always travel slowly to prevent excessive swinging of the load. The load must be carried as close to the ground as possible, and must not be lifted higher until it is almost in position. Where possible, avoid travelling the mobile crane across slopes or over potholes, depressions, soft ground etc. as these could de-stabilise the crane or load.
Page 100 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
19.0 Vehicle-Loading Cranes 1 9 .1
G e nera l u se
Vehicle-loading cranes are intended to be mounted on a broad range of vehicles including flat bed trucks and prime movers. When originally introduced, vehicle-loading cranes were used for loading the truck on which they were mounted. However, with the introduction of larger capacity vehicle-loading cranes, these types of cranes are also used for traditional crane operations where either: 2.
The load is lifted from the vehicle bed to an elevated area at a workplace (e.g. lifting containers from the vehicle directly to the work area); or
3.
The load is lifted both to and from locations, remote from the vehicle on which the crane is mounted.
4.
While vehicle-loading cranes may be used for the applications stated above, the level of safety provided by the lifting set-up must not be less than if a mobile crane was used.
1 9 .2
C r ane a nd Ve hi cle Sui tab ili t y
Vehicle-loading cranes must only be mounted on vehicle types and models specified by the crane manufacturer. Failure to comply with this could lead to structural failure of the crane or vehicle, or make the crane combination unstable. The method of mounting the crane to the vehicle must be in accordance with the crane manufacturer’s specifications. Any adverse effects to both the vehicle and crane are to be taken into consideration. Welding the crane to the vehicle chassis is generally unacceptable because it can damage the chassis, and also leads to fatigue failure of the connection.
1 9 .3
R ated Ca pa ci ty Li mit ers
The purpose of the rated capacity limiter is to prevent movements that may increase load moment in excess of the rated capacity, and to also prevent an increase of the load radius or permissible stresses in the structure. Refer to Appendix 10 for the requirements.
1 9 .4
Op era ti onal I s s ue s f or V e hi c le -L oad ing Crane s
The vehicle-loading crane must be operated in accordance with the operator’s instruction manual provided by the crane manufacturer. Additionally, the following points must be complied with: 1.
Operators must be trained in the specific operation of the particular vehicle loading crane.
2.
If the load is out of the operator’s view at any stage during the lifting process, the movement of the load must be directed by a qualified banksman.
3.
The crane may only be used with all outriggers extended in accordance with the crane manufacturer’s instructions. Where multiple positions can be used on outrigger legs, the legs must be set up in compliance with the manufacturer’s load chart.
Page 101 of 247
4.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The crane must only be used so that it is level in accordance with the crane manufacturer’s specifications (usually not exceeding 1º or less).
5.
Timbers or other supporting pads specified by the crane manufacturer must be provided under the outrigger feet for every lift in every circumstance.
6.
Hooks must be provided with spring-loaded safety latches, and must be adequately maintained.
7.
Where it is possible to apply a side load to the crane hook, the hook must be provided with an appropriate swivel.
8.
The crane must never be used in pick-and-carry mode.
9.
Vehicle-loading cranes are not to be used for lifting persons.
10.
Where provided, spring lock-outs on the vehicle are to be activated during crane operation.
11.
The crane must only be used with a load suspended vertically from the hook. The crane is not to be used to drag a load across a supporting surface.
12.
The outrigger legs shall be clearly marked with ‘zebra striping’ to improve visibility. Refer to 16.3 –7 for details.
Page 102 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
20.0 Use of Tag Lines In certain circumstances soft lines may be used to assist in the handling of long and/or fragile items of cargo. These are often referred to as tag lines. It must be recognised that, whilst such aids may assist operations, their use does introduce some additional risks, as described below.
2 0 .1
Risks
Additional risks associated with the use of tag lines include the following: 1.
Potential injuries from dropped objects as a result of personnel handling cargo having to work in closer proximity to suspended loads than would normally be the case.
2.
Potential injuries resulting from personnel handling cargo being dragged across the handling area, through a heavy load rotating in an uncontrolled manner and the tag line being fouled in limbs or clothing.
2 0 .2
M ake - up o f Li ne s
1.
Make-up of lines includes the following:
2.
Tag lines must be made up from single, continuous length of rope.
3.
Preferred rope materials are Polypropylene or Manila.
4.
The minimum diameter of rope used shall be 16 mm.
5.
Apart from the knot attaching the line to the cargo, there must be no other joints or knots in the line.
6.
Tag lines must be of sufficient length to allow personnel handling cargo to work in a safe position well clear of the immediate vicinity of the load. In this regard the length of the line shall be not less than one and a half (1.5) times the maximum height above the handling area at which the arrangements will be used.
2 0 .3
I n U se
Whilst in use, precautions shall be observed as follows: 1.
Tag lines are an aid to positioning the load when landing, and as such must only be used when weather conditions would permit the lifting of the item without the use of such arrangements. It must not be assumed that, in conditions more severe than this, the use of tag lines will allow the operation to be completed safely.
2.
At all times personnel handling tag lines must work at a horizontal distance from the load equivalent to its height above the handling area, maintaining an angle between the line and the horizontal of not more than 45º.
3.
All sections of the line, including slack, must be kept in front of the body, between the handler and the load.
4.
Where two or more persons are handling the same line, all must work on the same side of the line.
Page 103 of 247
5.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Tag lines must be held in such a manner that they can be quickly and totally released. They must not be looped around wrists, or other parts of the body.
6.
Particular care must be taken when using tag lines whilst wearing gloves to ensure that the line does not foul the glove.
7.
Tag lines must not be secured or attached in any manner to adjacent structures or equipment. This includes the practice of making a “round turn” on stanchions or similar structures and surging the line to control the load.
8.
Where pre-installed lines are used, consideration shall be given to providing personnel with boat hooks or similar equipment to retrieve the lines without having to approach the dangerous area in the vicinity of the suspended load. An example of such circumstances would be when lines are attached to a load on the deck of a vessel, the load being then transferred to an offshore installation.
Page 104 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
21.0 Sling Wire Diameters and Master links The minimum wire rope diameter for the construction of wire rope slings attached to loads, which will be lifted offshore, is 13mm (1/2”) Any wire rope of a smaller diameter is very susceptible to impact damage and must not be used. The maximum number of lifting legs allowed on a single master link is two this is to avoid out-of-plane forces. It is permissible to have a third leg on a master link but only if it is to be used as a top lifting leg. Three and four leg sling sets must be fitted with quadruple assemblies i.e. a master link with two intermediate links.
21.1
Multi-leg S lings
When lifting with multi-leg slings, they are rated at a certain capacity from 0º - 45º to the vertical and this WLL shall not be exceeded even if the angle is less than 45º. When using slings in pairs however, you must be aware of the increased loadings in the slings when lifting at an angle.
Page 105 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
22.0 Pallets Only purpose built pallets in good condition, without broken boards and blocks shall be used for transporting of loads. Under no circumstances shall any type of pallet be used as a lifting device. For example, putting slings through wooden pallets to lift them and their contents is prohibited. Slings are likely to crush the pallet leaving the contents on top unsecured. Pallets shall be lifted by a forklift or other certified pallet-lifting accessory. When using pallet lifters (see fig 3) it must be ensured that the forks of the pallet lifter are of adequate length for the load to be lifted. When a load is lifted using a manually operated or semi-automatic pallet hook, the load must always be in a horizontal position or with a slight backward angle.
FIG 3 Pallets that require to be lifted from vessels offshore are required to be loaded into a container to facilitate the pre-slinging requirements.
Page 106 of 247
23.0
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Pre & Post-Use Checks and Safe Use of Lifting Appliances and Lifting Tackle
2 3 .1
I nt r odu c ti on
This Section gives the pre and post checks and brief descriptions of the more frequently used types of lifting equipment used on SMEP offshore platforms and onshore.
2 3 .2
Li fti ng Ap plia n ce s a nd Li fti ng Ta ckl e
The terms ‘lifting appliances’ and ‘lifting tackle’ will be encountered in this Section and throughout this section. Refer to the Glossary of Terms in Appendix 11 for further information
2 3 .3
I de nti fi ca tio n a nd Cert ifi cati on
Every item of lifting appliances, portable or fixed (used onshore or on an offshore platform) must have as a minimum the following legible markings: 1.
Unique Identification number.
2.
Working Load Limit (WLL) or Safe Working Load (SWL).
3.
The date of inspection and next due date.
WARNING:
IF AN ITEM OF LIFTING EQUIPMENT HAS NO UNIQUE IDENTIFICATION MARKING, NO WLL MARKING, DATE OF INSPECTION OR IF EITHER THE UNIQUE IDENTIFICATION MARKING, WLL MARKING OR DATE OF INSPECTION CANNOT BE READ WITH CERTAINTY. IT MUST NOT BE USED.
Page 107 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
24.0 Control Of Portable Lifting Appliances and Lifting Tackle All portable lifting appliances and lifting tackle shall be stored and controlled in a lifting equipment store. This also applies to portable lifting appliances and lifting tackle owned by contractors and sub-contactors using their lifting equipment on Shell Malaysia Exploration and Production offshore or onshore facilitates. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-ST (section 4.11 page 8)
2 4 .1
Eq uip ment S ta nd ard s
All portable lifting appliances supplied must comply with standards listed in appendix 2 of S M E P L i f t i n g a n d H o i s t i n g S y s t e m , EP200803208668, B r i t i s h S t a n d a r d s , I n t e r n a t i o n a l S t a n d a r d s , or an American Federal Specification. On no account must prototype lifting equipment be supplied without the express, written approval of SMEP's Lifting Technical Authority. If the need arises, SMEP shall, on occasion, restrict or forbid the use of equipment where problems develop/incidents occur.
2 4 .2
S t ora ge
Portable lifting appliances and lifting tackle must be housed in rigging stores (or similar storage areas) that are fitted with storage facilities e.g. racks, bins etc. The store shall be a purpose designated storage facility where the lifting equipment can be kept secure from unauthorised use. It may be either a transportable containerised rigging store or a controlled permanent store. The store shall include a secure quarantine area for storing equipment no longer fit for service. The stores must have a lighting system compatible with the platform/worksite’s power supply. Any electrical wiring systems in the rigging store must comply with current safety regulations and meet SMEP electrical specifications.
2 4 .3
C er ti fi cat i on /C ha ng e o ut
The portable lifting appliances and lifting tackle must be fully inspected, certified and suitable for 6 months service offshore, or at the worksite, in accordance with the latest revision of SMEP.EP72.ST.0032. The lifting appliances and lifting tackle will however be changed out prior to the 6 monthly inspection expiry date. When appliances/tackle cannot be changed-out they must be examined on site by the third party surveyor and the new colour code applied.
2 4 .4
Eq uip ment M ar ki n g a nd Tra cki ng
Each and every item of lifting equipment (including tackle) must be permanently marked, in accordance with section 5, to facilitate traceability and allow for tracking during its service on the platform or at the worksite.
Page 108 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Marking shall be by positively attaching a metal tag to the equipment. Where the attachment of a metal tag is not possible or practical, marking may be done directly on to the equipment but must not affect the integrity of the equipment. Method of marking lifting tackle and lifting appliances is given in section 5.
2 4 .5
Con te nts R egi ster a nd O t her Docume nta ti on
Documentation that must be available within a rigging store is listed below: 1.
A register of the rigging store's contents.
2.
Current certificate for each item of equipment in the store.
3.
An issuing and returns register, a "T" card, or similar system to facilitate the tracking of rigging store equipment.
4.
Manufacturer’s operating and maintenance instructions (or copies) as supplied with new equipment.
2 4 .6
R ig gi ng St ore C on tr ol
Lifting appliances and tackle used by SMEP personnel and its contractors’ will, when not in use be stored in an on-site ‘Rigging Store’. Whenever an item of lifting equipment is removed from the rigging store it must be ‘booked out’ in accordance with the booking `system (register, Tee card, or other system). Similarly it must be ‘booked in’ upon return to the rigging store. The rigging store shall be controlled by a person who has the necessary competence to inspect the lifting equipment before issuing and on its return to check whether it remains fit for service. Have a comprehensive knowledge of SMEP.EP72.ST.0032, and is approved by SMEP’s Lifting Technical Authority. The requirements for the Lifting Equipment Focal Point are detailed in Appendix 1, Competency Requirements, of the Lifting Equipment Management System, EP200803208668.
2 4 .7
C o l our C odin g
Each and every item of lifting tackle in the rigging store shall be colour coded in accordance with Section 6.
2 4 .8
Clea ni ng of Equi pmen t
Portable lifting appliances and lifting tackle returned to the store shall be checked for contaminants and cleaned if necessary prior to inspection and storage. Equipment that has been exposed to seawater splash/spray shall be washed with fresh water, without water pressure. Pressure jets must not be used as they can remove essential lubricants, or in the case of chain blocks may cause the lubricants to migrate to brake components, which requires to be free of lubricant. After washing, the lifting tackle or appliances shall be dried without the application of direct heat. Portable lifting appliances and lifting tackle shall not be immersed in lubricant, diesel etc. in an attempt to displace water, in the case of appliances it will penetrate into the brake components. The load chain and components that are clearly visible without dismantling of the appliance i.e. pawl pivot spring etc may be lightly lubricated. Care must be taken to avoid lubricant
Page 109 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
entering the brake components and as precaution, before applying the lubricant the brake shall be closed by operating the appliance in the hoisting direction.
2 4 .9
M ai n tena n ce and I n spec t i o n
The supply contractor is responsible for the maintenance, inspection, and where necessary overhaul, and re-certification of the lifting equipment in accordance with the latest revision of SMEP.EP72.0032 . It is SMEP's requirement that all items of lifting equipment shall be certified at the frequencies stated in SMEP.EP72.ST.0032. Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-ST (section 4.7 page 6)
2 4 .10
D am a ged Li f ti ng Eq ui pme nt
When an item of lifting equipment is found to be defective, it shall be placed in a clearly marked quarantine area and a third party lifting tackle inspector or surveyor shall be called to decide on one of the following courses of action to be carried out: Equipment, which cannot be repaired, will be colour coded RED and labelled “DO NOT USE” and be disposed off at the earliest opportunity. Equipment, which can be repaired, shall be colour coded RED, and clearly labelled as unfit for continued use. A report, which will include a brief description of the repairs, required, must be attached to the item. A copy of the report for equipment, that cannot be safely used until repaired, must be submitted to the platform or worksite Lifting Equipment Focal Point (LEFP).
2 4 .11
R eti reme nt of Li fti ng Eq ui pme nt
Lifting equipment shall be retired (scrapped) when it has reached the end of its useful life or is damaged beyond economic repair/re-certification. SAP shall be updated accordingly. All lifting equipment to be scrapped shall be disposed off in such a way that the equipment cannot be re-used.
2 4 .12
C o n tra c t ors U si ng T heir Own Li f ti ng Eq ui pm e nt On S ME P P lat for m s/W or ksi te s
Contractors equipment shall be as per 14.4.6 and in addition must comply with the following:
2 4 .12 .1
Eq uip ment M ar ki n g/ Tr a ckin g
To distinguish contractor’s equipment from site/platform rigging store equipment, contractor’s equipment will require some additional (readily identifiable) identification.
2 4 .12 .2
Eq uip ment Re gi st er a nd Ot he r D oc u me nta ti on
Where a rigging store, or smaller quantities of lifting equipment/tackle are used on Shell Malaysia Exploration and Production platforms, the following is required: 1.
A register of the rigging store's content
2.
Current certificate for each item of equipment.
Page 110 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
An issuing and returns register or similar system to facilitate tracking of the equipment.
4.
Manufacturer’s operating and maintenance instructions (or copies) as supplied with new equipment.
2 4 .13
Pr e -U se I n sp e cti o n - Ba sic R eq ui rem en t s
Whenever lifting equipment is inspected prior to use the first items that must be checked are: 1.
Item identity number
2.
SWL or WLL
3.
Date of Inspection
4.
Examination colour code (if applicable)
Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-ST (section 4.9.2 page 7)
Page 111 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
25.0 Pre-use checks for lifting appliances not in use for an extended period of time In cases where lifting appliances are not used for an extended period of time the user shall ensure that the competent person specifies a special programme of pre-use checks and inservice inspections and thorough examination before it is used. The extent and thoroughness of this programme depends not only on the length of the period that the lifting appliance was out of use but also on the location of the lifting appliance during this period. Lifting appliances standing under cover or inside a workshop might require very little extra inspection. Lifting appliances that have been out of use in the open and therefore exposed to the weather and atmospheric pollution, etc. might require an extensive appraisal to ensure fitness for work. The programme of pre-use checks and in-service inspections must contain, as a minimum, the following checks: 1.
Any checks that are recommended in the manufacturers instructions for the lifting appliance.
2.
Checking all hoist chains/ropes for signs of corrosion/degradation and damage and ensuring that there is thorough lubrication.
3.
Checking all linkages for evidence of seizure or partial seizure and ensuring that there is correct lubrication.
4.
Checking for correct functioning of all the safety devices.
5.
Checking seals or other components for evidence of deterioration.
6.
Checking for corrosion on the structure, components, linkages etc.
7.
Checking for structural integrity, for example cracks, dents, missing components.
8.
Testing of every motion for several minutes without load and then repeating the test with a load.
2 5 .1
Eq uip ment Id e ntif i cat io n Ma rki ng s
2 5 .2
I de nti fi ca tio n Nu mb er/ Mar k
All items of lifting equipment must have a permanent, unique means of positive identification relating to ownership, e.g. stamped number, attached plate or label. If the identity of an item of lifting equipment cannot be found it must not be used. For positive identification purposes the equipment identification number must be used on all certification and records relevant to that item of lifting equipment. (Refer to Section 5)
25.3
Col our C oding Sy stem
SMEP require that all lifting equipment owned by them, or used on their worksites or where SMEP has the prevailing influence, be thoroughly examined at fixed intervals. (Refer 6.3.1) A colour code system is used by SMEP to indicate to the end user that item of lifting tackle has undergone a 6 monthly examination. The colour (code) is changed at ‘set’ 6-monthly intervals
Page 112 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
and lifting tackle shall only be used if they are displaying the current colour code. The colour code for the next 6-month period will always follows the sequence, Green, Blue and Yellow. (Refer section 6)
2 5 .4
Do cu me nta ti on Ac c o mpa nyi ng Li fti ng Eq ui pm en t
The following documentation shall accompany an item of lifting equipment and must be available to the end user if/when required. 1.
Certificate of Conformity
2.
Certificate of test and examination (if applicable).
3.
Operating and Maintenance Instructions.
Page 113 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
26.0 Wire Rope and Wire Rope Slings CAUTION:
ALWAYS WEAR LEATHER GLOVES WHEN HANDLING ANY FORM OF WIRE ROPE.
2 6 .1
W ir e R ope
Wire rope is manufactured from individual steel bars that are 'drawn' to size through a series of dies, reducing the diameter of the bar each time until a wire of the desired diameter is obtained. Individual wires are then formed and wound into strands. The strands are then wound together around a central core to form the rope (see Fig 1). The core of the rope can be of fibre or an additional steel strand. The number of wires in a strand and the number of strands in a rope are known as the 'construction' of the rope. There are a variety of arrangements in wire rope construction; designs are produced to give special characteristics such as flexibility, rotation resistant, crush resistant, etc.
CORE: FIBRECORE = FC INDEPENDENT WIRE ROPE CORE = IWRC
CORE WIRE ROPE STRAND
WIRE CENTRE WIRE
Fig 1 Wire Rope Terminology
2 6 .2
T ype s of Lay
A wire rope comes in a verity of lays, however the most common are Ordinary lay and Lang's lay. ‘Ordinary lay’ is the term used to describe a wire rope in which the wires in the strands are laid one way and the strands in the rope laid in the opposite direction. Ordinary lay rope is completely stable, to the extent that a slight amount of ‘turn’ will always come out of a 6 stranded rope when a load is applied. However, it normally returns to its former position when the load is released. ‘Lang's lay’ is the name applied to the type of rope in which the wires in the strands and strands in the rope are laid in the same direction. The two lays can be readily distinguished: with Ordinary lay the individual wires appear to run along the rope, while in Langs lay they run diagonally across it.
Page 114 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
2 6 .3
W ir e R ope Sli ng s
Wire rope slings are manufactured in accordance with BS EN 13414-1, from wire rope, which meets the requirements of BS EN 12385-4, or an equivalent International Standard. Wire rope slings are the most commonly used lifting accessory and require care in handling and attention in use. They must be protected from severe wear, abrasion, impact loading, crushing and kinking or similar abuse. Wire rope slings must be adequately protected from crushing and chafing damage by the use of adequate packing. The more common types of wire rope sling are shown on Fig 2.
Fig 2 Single Leg and Endless Slings
2 6 .4
S l in g Id e nt if i cati on
All single and multi-leg wire rope slings must have stamped on a permanently attached metal tag or on the ferrule (see Fig 3). 1.
Identity number.
2.
SWL.
3.
A sling must also carry the correct colour code.
IMPORTANT: THE CAPACITY OF A MULTI-LEG SLING IS STATED AS A SINGLE SWL, FOR ANY ANGLE BETWEEN 0° AND 45° TO THE VERTICAL, AT THE MASTER LINK.
Page 115 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Working Load Limit
ID No. & WLL Tag
Fig 3 Sling Identity As well as single leg sling options, they can be supplied as double leg slings fitted to a single link (known as a master link) or as multi-leg slings (3 or 4 legs) fitted to a master link
Fig 4 Multiple Leg Slings
Page 116 of 247
Effective Working Length
EWL
assembly Fig 4 shows typical arrangements.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
2 6 .5
Pr e -u se
The following covers wire rope and wire rope slings. 1.
Check sling unique identification and WLL are present and readable and current colour code is present.
NOTE: DESTROY (OXY-CUT) SLINGS THAT ARE FOUND TO BE UNFIT FOR USE, SO THAT THEY CANNOT BE ACCIDENTALLY RE-USED. 2.
Check for broken, damaged or kinked wires, which may have been caused by previous incorrect slinging of the load.
3.
Check for signs of abrasion and similar damage resulting from chafing action against the load or ground/deck.
4.
Check the rope for corrosion, crushed areas, high stranding, underlying, bird caging, kinks, bulges in the rope, core protrusion, gaps or excessive clearance between strands.
5.
There must be no evidence of heat burn, or pitting, (possibly from welding equipment) or similar such discolouration to the sling wires.
6.
Inspect end terminations for damage, deterioration and security
7.
Check sling /rope for broken wires.
8.
Ensure that sling thimbles are secure in the sling eyes. It is permissible for a thimble to display a small amount of movement; the amount shall not be such that the thimble may become dislodged.
9.
Check all attached fittings, i.e. hooks, rings, links, etc.
NOTE: IF IN DOUBT DO NOT USE AND SEEK ADVICE FROM THE PIC OR WORKSITE SUPERVISOR.
2 6 .6
Sa f e U se
1.
When using slings observe the following:
2.
Protect them from wear, abrasion, impact loading, crushing and kinking or similar
abuse. 3.
Always use a sling with a greater WLL than the anticipated weight of the load if: a.
The exact load weight is unknown.
b.
There is a possibility of shock or dynamic loading.
c.
There will be an increase in load, through wind effect.
d.
When the load has to be lifted over vulnerable plant (because there is no alternative route).
4.
Do not assess the required WLL of a multi-leg sling by dividing the load weight by the number of sling legs. There is no way of knowing that all sling legs will carry equal amounts of the load. With multi-leg slings, it is possible that two legs could be carrying the majority of the load whilst the other sling legs just balance the load. If it is obvious that the load is unbalanced, the leg tension (not the weight of the load) in
Page 117 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
the sling legs carrying the majority of the load must be assessed when determining the sling WLL required. If in doubt do not sling the load but seek advice from the PIC.
NOTE: FOR MULTI-LEG SLINGS THE WLL IS QUOTED FOR AN ANGLE OF THE LEG TO THE VERTICAL, AT THE MASTER LINK, OF 0° TO 45°. 5.
Be aware that tension in sling legs varies with the angle of the leg to the vertical at the hook. A 'sling angle' is usually denoted by the angle of the leg to the vertical at the lifting point, which is: a.
With two- leg slings, the angle of the leg to the vertical (0° to 45°).
b.
With three-legged slings, the angle between one leg and the vertical (0° to 45°).
c.
With four-legged slings, the angle between one leg and the vertical (0° to 45°).
6.
Never use a sling that is knotted or kinked.
7.
Prepare the load landing area. Most loads can be lowered on to timber battens allowing the slings to be withdrawn. Never land a load on to the load slings
8. 9.
Keep slings away from welding or cutting operations. A multi-leg sling must not be used if, when fitted to the load, the angle from the vertical at the master link is greater than 45°; sling with longer legs must be selected.
10.
Take care not to 'kink' wire rope or a sling. A kink in a sling or rope will distort the sling/rope, severely affecting its strength (WLL) causing it to be removed from service and destroyed. Kinks are usually formed in one of two ways: a.
Bad slinging practices, e.g. tensioning a sling over an acute angle, or round too small a diameter.
b.
By pulling on a loop accidentally formed in a sling. If the sling is pulled instead of 'untwisted', a kink will quickly form in the sling (see Fig 5).
Fig 5 How a Kink is Pulled into a Wire Rope 11.
Do not wrap a wire rope around a hook (see Fig 6).
Page 118 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 6 Never Wrap a Wire Rope Round a Hook 12.
Always avoid bending a sling around small diameters. The minimum radius around which a sling shall be bent is 6 times the diameter of the rope.
13.
Do not join two slings together by, 'threading the ey e' (see Fig 7). If two slings are to be joined together, they must be joined with a shackle of at least the same WLL as the slings to be joined.
Fig 7 Joining Slings 14.
Never shorten a sling by tying a knot in it. A knot will cause severe kinking of the sling when the load is lifted, an immediate reduction in the WLL of the sling, and result in the sling being removed from service and destroyed.
15.
Semi-permanent terminations of wire ropes are frequently made using wire rope clips. These provide a quick and easy way to terminate wire ropes and when properly applied including the insertion of a thimble in the eye of the sling, and the application of sufficient torque to the securing nuts, provide up to 80% of the strength of the original rope. Wire rope slings that are made using this method shall not be used for lifting.
U-Bolt rope grips must not be used. The only acceptable rope grip is the double-saddled type (fist grip) Refer to Appendix 8 for installation instructions
Page 119 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Figure 8 Application of Rope Grip's 16.
When using a sling in a choke-hitch mode, do not force the eye of the sling into closer contact with the load. This dangerous malpractice and is often called "battening down". The choke-hitch must be allowed to form its own 'natural angle’, which will be about 120° (see Fig 9). If forced down, the angle between the sling 'legs' will probably increase beyond 120° and become dangerous.
17.
The slinging of pipes and tubulars is a very common lifting operation.
Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-G01(section 2.1 page 13)
Fig 9 Do Not Batten Down Slings The slings must be double wrapped with a choke hitch taking care not to cross over the wires on the underside of the pipe or tube bundle (Fig 9). The choke hitch requires to be pulled tight to contain the bundle and secured using an wire clamp (i.e. Asbro clamp) or a fist grip, If using a fist grip, a tie wrap must then be fitted to prevent the reeved eye slipping over the fist grip, in case the bundle loosens in transit.
Page 120 of 247
a.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The sling positioning must be approximately 25% (of the total length) in from either end of the tubular (Fig 9).
b. c.
Each sling shall have a WLL at least equal to the gross weight of the load. Ensure that the correct length of slings are used. The recommended safe lifting angle of the sling leg is 30 degrees from the vertical; the maximum lifting angle must never exceed 45 degrees from the vertical
Do not bend a sling round sharp corners of a load. Use wooden packing to protect the sling from sharp edges and to generally increase the radius around which the sling must bend. The wrapping of a fire blanket, or similar, around a beam is cosmetic and unacceptable.
Fig 10 Packing Out a Load to Prevent Damage to Load and Slings 18.
Multi-leg slings must not be used if there is a possibility that they will damage the equipment to be lifted. Alternative lifting arrangements must be made.
19.
When lifting a load, if there is the slightest doubt as to the stability of the load, it must be slowly lifted clear of the ground, if the load then tilts, it must be lowered immediately and re-slung in a more stable position.
20.
Tag lines must be attached to the load and not to the lifting gear.
Page 121 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
27.0 Wire Clamp (ASBRO) Pre-Use Inspection Wire clamps must be visually inspected before they are used as follows: 1.
Check the clamp is of the correct size for the wire rope.
2.
Inspect the saddle for excessive wear, cracks, deformity and impact damage.
3.
Inspect the claw for excessive wear, cracks, deformity and impact damage.
4.
Inspect the wedge for excessive wear, cracks, deformity and impact damage and check that the wedge lock is free to move
2 7 .1
R eje ct i on
The clamp needs to be rejected when there is any obvious excessive wear, cracks, deformity or impact damage or if the clamp allows the rope to slip through when landing the bundle thus allowing the bundle to become slack.
2 7 .2
C a re a nd ma in tena n ce
The clamps must be inspected for damage after removing from sling. The Wedgelock shall be greased, if required, and the clamp reassembled and stored in a box marked with the correct size/diameter for future use. The wire clamp must be stored in a dry atmosphere.
CAUTION: AFTER LANDING LOAD ON THE TRUCK OR VESSEL, CHECK THAT THE BUNDLE REMAINS SECURE AND THERE IS NO BACK SLIPPAGE OF THE ROPE THROUGH THE CLAMP. BEWARE OF TUBULARS ROLLING OUT TO A FLAT POSITION. THERE MAY BE A DANGER OF LIMBS BEING TRAPPED, IF ANY BACK SLIPPAGE BECOMES APPARENT AND/OR THE BUNDLE BECOMES SLACK, THE CLAMPS MUST BE REPLACED. It is a requirement that individual tubulars are double wrapped. If the tubular or load is being lifted and laid down more than once, it may also be advisable to lock the choke with a wire clamp or fist grip.
2 7 .3
A f ter Use
Proceed as follows: 1.
After use and before storing, check slings for damage and deterioration in the same manner as for pre-use inspection.
2.
Never leave slings laying on the ground/deck where they will be exposed to environmental hazards such as chemical spillage, mechanical damage and soaking from water accumulation.
3.
Return slings to the rigging store and complete ‘returns’ procedure.
Page 122 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
28.0 Chain Slings and Fittings It is SMEP policy not to use chain slings for general lifting operations. However, chain slings are used for lifting skips and lifting barrels / steel drums, or similar, from containers. Various chain sling configurations are shown on Fig 11. Some chains are shown with chain ‘shortening clutches’.
Fig 11 Chain Sling Configurations
The rating of chain slings is based on the uniform load method, which give the following results: Single leg sling
=
1.0
x
SWL of a single leg
Double leg sling
=
1.4
x
SWL of a single leg from 0° to 45°
Three and Four leg sling
=
2.1
x
SWL of a single leg from 0° to 45°
Double leg sling
=
1.0
x
SWL of a single leg from 45° to 60°
Four leg sling
=
1.5
x
SWL of a single leg from 45° to 60°
2 8 .1
B ar rel S li ng s
Barrel slings as shown in Fig 12 must be used for lifting a single barrel/drum only. When more than one barrel is to be lifted in one lift, a drum cage must be used.
Page 123 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 12 Barrel Sling
2 8 .2
Pr e -u se
Chain and barrel sling must be visually inspected before they are used as follows: 1.
Check sling unique identification and WLL are present and readable and current colour code is present.
2.
Ensure the grade of the chain sling is suitable for lifting duties i.e. grade 8, 10 etc.
3.
Check for stretch in the individual legs.
4.
Check each leg for distortion of links e.g. bends, twists, corrosion, elongation and nicks.
5.
Check for wear between chain links and load pins.
6.
Check end fittings e.g. hooks, connectors etc in accordance with the appropriate sections of this standard.
7.
Check all coupling components are free from distortion; cracks and the securing/ load pins are secured.
8.
Inspect end terminations for damage, deterioration and security.
9.
Check all attached fittings, i.e. hooks, rings, links, etc.
NOTE: DESTROY (OXY-CUT) SLINGS THAT ARE FOUND TO BE UNFIT FOR USE, SO THAT THEY CANNOT BE ACCIDENTALLY RE-USED.
2 8 .3
Sa f e U se
When using chain slings observe the following: 1.
Protect them from wear, abrasion, impact loading, crushing, or similar abuse.
2.
Always use a sling with a greater WLL than the anticipated weight of the load if: a.
The exact load weight is unknown.
b.
There is a possibility of shock or dynamic loading.
c.
There will be an increase in load, through wind effect.
Page 124 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
d.
When the load has to be lifted over vulnerable plant (because there is no alternative route).
3.
Do not assess the required WLL of a multi-leg sling by dividing the load weight by the number of sling legs. There is no way of knowing that all sling legs will carry equal amounts of the load. With multi-leg slings, it is possible that two legs could be carrying the majority of the load whilst the other sling legs just balance the load. If it is obvious that the load is unbalanced, the leg tension (not the weight of the load) in the sling legs carrying the majority of the load must be assessed when determining the sling WLL required. If in doubt do not sling the load but seek advice from a supervisor.
NOTE: 4.
FOR MULTI-LEG SLINGS THE WLL IS QUOTED FOR AN ANGLE OF THE LEG TO THE VERTICAL, AT THE MASTER LINK, OF 0° TO 45°.
Be aware that tension in sling legs varies with the angle of the leg to the vertical at the hook. A 'sling angle' is usually denoted by the angle of the leg to the vertical at the lifting point, which is: a. b.
With two- leg slings, the angle of the leg to the vertical. With three-legged slings, the angle between one leg and the vertical (0° to 45°).
c.
With four-legged slings, the angle between one leg and the vertical (0° to 45°).
5.
Never use a sling that is knotted.
6.
Prepare the load landing area. Most loads can be lowered on to timber battens allowing the slings to be withdrawn. Never land a load on to the load slings
7.
Keep slings away from welding or cutting operations.
8.
A multi-leg sling must not be used if, when fitted to the load, the angle from the vertical at the master link is greater than 45°; sling with longer legs requires to be selected.
2 8 .4
A f ter Use
Proceed as follows: 1.
After use and before storing, check slings for damage in the same manner as for preuse inspection.
2.
Never leave slings laying on the ground/deck where they will be exposed to environmental hazards such as chemical spillage, mechanical damage.
3.
2 8 .5
Return slings to the rigging store and complete ‘returns’ procedure.
B ar rel Li f ter s
Barrel lifters are used to lift barrels vertically from half-height containers. This type of barrel lifter is only used to lift the barrel from a container and place it on the deck beside the container. Lift height must be minimised and personnel must not be allowed beneath the
Page 125 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
barrel. Various manufacturers produce this type of barrel lifter and a typical top (vertical) barrel lifter is shown in Fig 13. Care must be taken when using a ‘barrel lifter’ to ensure that the barrel to be lifted is of standard size. Non-standard / modified barrels must not be lifted with this type of barrel lifter. They will not ‘fit’ the barrel lifter and may drop when lifted. The vertical barrel lifter must only be used to lift barrels from containers and place them on the deck alongside the container.
Fig 13 Typical (Vertical) Barrel Lift Device
CAUTION: DO NOT USE BARREL LIFTERS FOR THE PURPOSE OF TRANSFERING BARRELS AROUND THE PLATFORM/PLANT. THE USE OF THIS TYPE OF LIFTING APPLIANCE IS RESTRICTED TO LIFTING BARRELS FROM A CONTAINER AND PLACING THE BARREL ON THE DECK ALONGSIDE THE CONTAINER. BARREL LIFTERS SHALL NOT BE USED IN CONNECTION WITH LIFTING OPERATIONS USING OFFSHORE CRANES.
Page 126 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
29.0 Man-Made Fibre (Webbing) Slings Webbing slings, where ever possible, shall not be used for general lifting either onshore or offshore. Webbing slings of nylon or other man made fibres are extremely difficult to examine by visual inspection only. Weakening of the main body of the sling or stitching by chemical or mechanical means can all too easily remain undetected until the sling is loaded. Table 1 shows the webbing sling material colour code and WLL. Generally man made fibre slings are used for slinging fragile loads or for suspending loads where the equipment coating has to be protected i.e. chrome tubulars. Generally, the width of a webbing sling governs the WLL and approximates to 1 tonne per 50mm of width for Simplex (single thickness) slings and 1 tonne WLL per 25mm width for Duplex (double thickness) slings. Man-made fibre (webbing) slings are manufactured in various formats e.g. as flat web slings with soft eyes, hard eyes or endless to suit specific requirements. They can also be supplied as “round” slings (see Fig 14). Webbing slings are manufactured from Polyester, Nylon or Polypropylene. Each material has particular design properties, each of which shall be considered and may affect a webbing sling selection process.
Page 127 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 14 Webbing Slings Material
Identification colour for material (found on label)
Polyamide
Green
(Nylon) Polyester
Blue
Polypropylene
Brown
Table 1 Fibre Sling Colours Do not use a webbing sling as a transit sling.
2 9 .1
W ebb ing ( Ro u nd a nd Fla t ) Sli ng W L L C o l o ur C odi ng
The colour of the outer canvas cover of a round sling denotes the WLL of the sling (Table 2). SLING WLL (TONNE)
COLOUR OF OUTER COVER
1
VIOLET
2
GREEN
3
YELLOW
4
GREY
5
RED
6
BROWN
8
BLUE
10
ORANGE
Table 2
Webbing (Round and Flat) Sling WLL Colour Codes
Page 128 of 247
2 9 .2
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Pr e -u se
Webbing slings shall not be used for general lifts, and must be used only under strict control whenever delicate, fragile or specialist lifts are required. Fibre slings must be visually inspected before they are used as follows: 1.
Check the sling unique identification, WLL are present and readable and correctly colour coded.
2.
Pay extra attention to webbing slings when inspecting for damage, look for: a.
Chafes to the sling. These must be viewed critically, destroy sling if chafes are severe.
b.
Local abrasions will cause a serious loss of strength and the sling must be destroyed.
c.
Cuts, particularly at the edge stitching, will result in a serious loss of strength and the sling must be destroyed.
d.
Friction burns can be recognised by a hard, smooth, shiny surface on the web, which will be brittle to the touch, if found, the sling must be destroyed.
3.
Check for chemical attack, which can be recognised by weakening or softening of the material such that surface fibres can be plucked or rubbed off, as a powder in extreme cases. Destroy sling if chemical damage is found.
4.
Check webbing seams for deterioration.
5.
Give special attention to webbing sling eyes. Check for damaged stitching and cuts to the inner surfaces. If there is evidence of damage at the sling eye destroy the sling.
6.
If mildew is found, wash off with fresh water do not use detergents. Mildew does not affect the strength of the webbing and may be removed by washing in water only.
2 9 .3
Sa f e U se
Man –made fibre slings may only be used: 1.
Where there is no practical alternative.
2.
Where wire rope could cause crushing or surface damage to unprotected loads (e.g. piping with specialised coatings, rotating components from machinery, fragile equipment etc).
3.
For awkward lifting, where risk would be reduced
4.
For applications where the design specifies man-made fibre slings.
Observe the WLL mode factor for webbing slings as shown on Fig 15.
2 9 .4 1. 2.
Pr ohib ited Li fts Man-made fibre slings are prohibited in the following situations: Where sharp edges, rough or abrasive surfaces could cut or tear the sling (e.g. I beams, etc.)
3.
Where exposed temperatures in excess of 80 degrees Celsius may occur.
Page 129 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
4.
Where exposure to chemicals is likely (e.g. acids, alkalis, oil, solvents and paints).
5.
For pre-slinging loads associated with dynamic factors, such as vessel operations.
6.
For any load that may rotate in the sling.
2 9 .5
Sp e ci al A pp li cati on s
Any sling used in support of fast rescue boats shall be: 1.
Made of continuous fibre construction
2.
Have extra UV protection
3.
Be replaced annually or sooner if required.
There may be the rare occasions where a man-made fibre sling may be exposed to a dynamic lift, shock or snatch conditions i.e. lifting of chrome tubulars offshore. Under such circumstances the lifting operation shall: 1.
Be considered as a complicated lifting operation and thus be subject to the additional requirements for job planning and operating practice. Refer to Section 9.9
2.
Utilise slings with a working load rating that is double the actual load being lifted (e.g. 5 tonne straight lift requires a sling with a 10 tonne working load rating).
CAUTION: 1.
A NYLON (POLYAMIDE) SLING CAN LOSE UP TO 15% OF ITS WLL WHEN WET.
To minimise loss of strength when using a webbing sling eye on a hook, the hook bowl must have a width of more than one-third the inside length of the webbing sling eye.
2.
Protect a webbing sling when passing it round a surface that may cause damage to the sling.
3.
Do not permit the eye of a webbing sling to be opened in excess of 20° to avoid excessive load on the stitching.
4. 5.
Do not cause friction heat in a webbing sling by pulling it round a solid object. Do not allow a webbing sling to contact hot pipelines or hot pressure vessels. Webbing slings are adversely affected by heat.
6.
Ensure that a flat webbing sling is loaded evenly across its full width.
7.
Under no circumstances shall two slings be joined together by 'threading the eye'. If two webbing slings have to be joined together they must be joined with a shackle.
8.
Webbing slings must not be used as the primary lifting slings for the transportation of goods or cargo to or from a platform, except where noted above.
2 9 .6
A f ter U se
Carry out the following: 1.
Check sling(s) for damage, deterioration and contamination before storing. Damaged slings and chemically contaminated slings must be destroyed.
Page 130 of 247
2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
If a fibre sling is wet it must be thoroughly dried before returning to rigging store. Dry the sling by hanging it in a warm area, not over/on hot pipe work where excessive heat could damage the sling.
3.
Return sling(s) to rigging store and ‘complete ‘returns’ procedure.
CAUTION:
FIBRE SLINGS WILL DEGRADE IN ULTRAVIOLET LIGHT AND MUST BE STORED AWAY FROM SUNLIGHT AND OTHER SOURCES OF ULTRAVIOLET LIGHT.
Fig 15 Fibre Sling - Mode Factor
Page 131 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
30.0 Hooks A variety of hook designs will be encountered on SMEP worksites and platforms however, all hooks must be of the ‘safety hook’ type, i.e. a hook that has a mechanical latch arrangement that prevents the hook from opening until manually released. Fig 16 shows two of the more commonly used hook types. A hook that does not have a safety latch must not be used. The scissor action self locking type hook shown in Fig 16, or the BK type are commonly known as a ‘scissors type’ safety hook. The geometry of these hooks is such that as long as the load is passed vertically through the centre line of the hook, the applied forces will positively close the hook. When the hook closes a cam-lock will prevent the hook from opening. To open the hook the cam-lock requires manually unlatching. This design makes the hook one of the safest types under normal operational circumstances. However, care must be exercised when using this type of hook to ensure fingers are not pinched in the scissor action when used for lifting operations to and from a moving marine vessel, they must be fitted with the additional trigger release handle. (see fig 16A)
The scissor type hook can however, be unlatched accidentally if the hook is subject to shock loading in the opposite direction to which load is normally applied. Scissor action self locking type hooks fitted to pennants must be fitted with the additional trigger release handle Fig 16A.
Fig 16 Hook Types
Page 132 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 16A Scissor Hook with trigger release handle
3 0 .1
Pr e -u se
Hooks must be visually inspected before they are used as follows: 1.
Check hook WLL is present and readable.
2.
Check that wear on the bearing surface of the hook is not excessive and that there are no stress/fatigue cracks, or any form of damage (see Figs 17 and 18).
Fig 17 General Hook Inspection
Page 133 of 247
3 0 .2
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
S ci ssor H ook I n sp e cti on
The scissor type self-latching hooks shall be inspected as follows: 1.
Check generally as shown in Fig 17.
2.
Physically close the hook and check that hook closes correctly.
3.
With hook closed attempt to pull hook apart and check gap between closing faces of hook. The gap on smaller hooks (less than 10 tonnes) must not exceed 2mm and on larger hooks (greater than 10 tonnes) the gap must not exceed 4mm (see Fig 18).
4.
View the hook edgeways and check for ‘twist’. If either the bottom or the top of the hook is twisted beyond the centreline the hook must not be used.
5.
Check hook swivel for free rotation, damage and wear.
6.
Confirm that hook latch mechanisms operate freely and has a positive action.
Fig 18
3 0 .3
Scissors Type Hook Inspection
Saf e U se
Observe the following: 1.
The WLL of a hook applies only when the load is correctly positioned on the load line of the hook. If the hook is eccentrically loaded, or if a load is applied other than on the hook load line, the hook WLL is greatly reduced.
2.
Do not attach more than two sling eyes directly on a hook. If more than two slings need to be attached to a hook, a suitable shackle must be used between the hook and the slings’ (see Fig 19).
Page 134 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 19 4.
Do Not Overcrowd a Hook
Where the load will have a tendency to rotate when lifted, use a swivel hook, or insert a swivel link between load hook and lifting rope.
5.
Always check to ensure that the hook safety latch, or on scissors type hooks the latch release cam has closed correctly before allowing the load to be lifted.
6.
Do not side load, tip load, or back hook (see Fig 20).
Fig 20 Incorrect Hooking Methods
3 0 .4
A f ter Use
1.
Check hook as for pre-use checks.
2.
If applicable, return hook to rigging store, and complete ’returns’ procedure.
Page 135 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
31.0 Shackles All shackles used by SMEP shall preferably be of the alloy steel variety and designed and manufactured in accordance with the US Federal Specification RR-C-271D grade ‘A’, BS EN 13889 or an equivalent international standard. The use of higher tensile steel shackles is to be avoided for reasons of safety (e.g. A high tensile steel shackle of similar size to an Alloy steel shackle is approximately only half the strength - confusing the two could lead to inadvertent overload).
NOTE: MILD STEEL SHACKLES SHALL NOT BE USED UNDER ANY CIRCUMSTANCES. Two basic types of shackle will be encountered on SMEP worksites and offshore platforms (Fig 21). 1.
'Safety-Anchor' shackle with bolt, nut and safety pin, which can have a Bow or Dee shape body.
2.
'Screw pin' shackle with a pin screwed into one body eye. This type of shackle can also have a Bow or a Dee shape body.
A Bow shackle is generally used where more than one attachment is to be made to the shackle, i.e. with multi-leg slings. A Dee shackle is generally used to link two items of lifting equipment together and restricted to one attachment only i.e. with single sling.
3 1 .1
Pr e -u se I nsp e cti on
Shackles must be visually inspected before they are used as follows: 1. 2.
Check shackle unique identification, WLL and colour code. Look for damage to the pin or body threads, distortion in any part of the shackle and obvious wear on the body or pin of the shackle. Also check for nicks, cuts, cracks or corrosion on any part of the shackle (see Fig 21).
3.
Where a shackle pin is designed to accept a locking split pin (safety shackle), the split pin must be in good condition and of the correct diameter and length see Appendix 9. “R” clips cannot be substituted for a split pin and must not be used.
4.
Ensure that the pin and the body are of the same grade material and that they ‘match’. If body and pin do not match the shackle must not be used.
When a shackle body is suspended from its crown on a piece of wire and tapped with a hammer it shall have a clear 'bell-like ring', if a crack is present the shackle will have a 'dead' sound.
Page 136 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 21 Shackle Inspection
3 1 .2
Saf e U se
When using a shackle, the following shall be observed: 1.
A shackle must be fitted and loaded such that the load line is on the centre line of the shackle and not in such a way that side loads are imposed on the body.
Fig 22 Correct and Incorrect Use of a Shackle with a Hook
Page 137 of 247
2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
To avoid side loads on a shackle fit loose spacer/shimming washers at each end of the shackle pin, or fit a shackle with a jaw opening 'gape' that fits the hook.
3.
Do not reduce the width between the jaws of a shackle by welding washers or spacers to the inside faces of the shackle jaws. Welding heat will seriously weaken the shackle, and invalidate certification.
4.
When a shackle is used to secure the top block of a set of rope blocks the load on the shackle (and anchor) is increased by the value of the hoisting effort. Care requires to be taken to ensure that the structure, attachments and shackle are all of adequate WLL.
Fig 23 Use of Shackle with Sheave Block
5.
Do not use a single rope (sling) passed over a shackle screw pin to lift a load (Fig 24). The load is unstable and if it shifts, the rope could unscrew the shackle pin.
Fig 24 Use of Slings with Shackles 6.
Always place the shackle with the pin uppermost in the hook and with the sling eyes located in the shackle body (Fig 24).
Page 138 of 247
3 1 .3
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
A f ter Use
On completion of use: 1.
Thoroughly clean the shackle and inspect the shackle in accordance with pre-use procedures.
2.
Coat threads and body of shackle with light machine oil. Do not separate pins and shackle bodies. A shackle must always be stored as a complete, certified unit.
3.
Return the shackle(s) to rigging store and complete ‘returns’ procedure.
Page 139 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
32.0 Eyebolts Eyebolts are one of the most widely used items of lifting tackle, however, only collared eyebolts must be used.
Fig 25 Types of Eyebolt and Eyebolt Terminology
32.1
Eyeb olt with Link
This type of eyebolt is preferred for general lifting (see Fig 25). It can be used where loading cannot be kept to a single plane. An eyebolt with a link can be loaded in any direction to full WLL provided that the angle of the load to the axis of the screw thread does not exceed 15°. For greater angles (up to 45°) the WLL requires to be de-rated by a reduction factor of 0⋅65.
3 2 .2
C o l l a r E yeb ol t
A collar eyebolt (see Fig 25) must have a thread that is run out and recessed under the collar, so that it seats correctly on the load. The WLL of a collar eyebolt is stated for vertical lifts only. A pair of collar eyebolts can however be used in conjunction with a shackle and two-leg sling to lift at an angle to the vertical but the WLL must be de-rated. For angles between 0° and 45° collar eyebolts must be de-rated by 50%
Page 140 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Where more than one eyebolt is used to lift a load, the eyebolts must have the same WLL. In instances where the eyebolts will not be equally loaded, it is essential that each eyebolt is of adequate capacity. The plane of each eyebolt shall align with the point of lift, e.g. the hook, with a maximum variation of 5° either way.
WARNING
DYNAMO EYEBOLTS, COLLAR-LESS EYEBOLTS WITH A SCREWED SHANK, OR THREAD DIAMETER OF LESS THAN 12mm ARE NOT TO BE USED FOR LIFTING.
CAUTION
EYEBOLTS MUST NOT BE USED FOR OFFSHORE LIFTING.
3 2 .3
Pr e- u se I nsp e cti o n
Eyebolts must be visually inspected before they are used as follows: 1.
Check eyebolt unique identification and WLL, are present and readable, and colour coded.
2.
Generally clean the eyebolt and inspect the eyebolt for bent shank, deformed eye, cracks and nicks and in particular for thread damage. If defects are found the eyebolt must be scrapped.
3.
Check that the threaded hole into which the eyebolt is to be fitted is clean, its thread is in good order and there is no build-up of dirt/grease in the bottom of the hole that will prevent the eyebolt collar from seating.
Fig 26 Eyebolt Inspection
Page 141 of 247
3 2 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Saf e U se
Observe the following: 1.
Check that the eyebolt thread and the hole thread are compatible. If threads are mismatched any attempt to force-mate will result in a serious reduction in lifting capacity and will render both threads (male and female) unfit for further use.
2.
Check that the surface area around the hole (under the eyebolt collar) is clean, and will not hinder the eyebolt collar from seating all round. The threaded hole receiving an eyebolt must have sufficient thread depth to ensure that the eyebolt collar will seat before the eyebolt thread reaches the bottom of the threaded hole.
3.
Do not fit a hook directly on to an eyebolt; use a shackle (Fig 27).
Fig 27 Use of Eyebolt with Shackle 7.
Do not use excessive leverage to tighten an eyebolt that will not seat correctly with normal leverage (Fig 28). Over-tightening of an eyebolt can cause stretching of the shank under the collar resulting in serious (but hidden) damage, which will cause a reduction in the WLL. Use no greater leverage than a spanner compatible with the eyebolt thread size.
Fig 28 Eyebolt Tightening
Page 142 of 247
8.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
If a single eyebolt is used for lifting and there is a possibility that the load will revolve or twist, a swivel must be used in the lifting gear to prevent the eyebolt from being unscrewed.
9.
When using more than one collar eyebolt for lifting if the plane of an eyebolt will not align with the point of lift, a shim may be used under the eyebolt collar. The shim thickness must not exceed half of one thread pitch and the outside diameter of the shim must be the same diameter as the eyebolt collar diameter (Fig 29).
Fig 29 Eyebolt Alignment 7.
Under no circumstances must an eyebolt be over-tightened in an attempt to achieve correct alignment.
8.
Eyebolts used in clearance holes with back nuts shall have some locking device fitted to the nut to prevent the nut from unscrewing. The nut shall be of a grade compatible with the eyebolt.
9.
Use a tapered washer if an eyebolt is used on a tapered surface (Fig 30).
Fig 30 Fitting Eyebolt to Uneven Surface 10.
When using eyebolts in conjunction with a two-legged sling ensure that the longest sling legs possible are used so as to minimize: a.
Inclined loading at eyebolts, and
b.
Angle at the hook from the vertical.
Page 143 of 247
3 2 .5
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
A f ter U se
On completion of use: 1.
When an eyebolt is removed ensure that the tapped hole is suitably protected against damage and deterioration. Check eyebolt for any damage that may have been incurred during use.
2.
Lightly coat with oil to protect machined surfaces, i.e. threads and underside of eyebolt collar.
3.
3 2 .6
Return eyebolt(s) to rigging store and complete ‘returns’ procedure.
Swi ve l H oi st Ri ng s
The swivel hoist ring performs a similar function to a link eyebolt but with a greater and safer range of out-of-vertical lift capabilities. The swivel hoist ring will swivel unrestricted through 360º and its lifting bail ring will pivot through 180º (Fig 31). There is no reduction in SWL for angled lifts between 0º and 90º. Hoist rings are available with either UNC or Metric thread sizes; the coloured washer on the swivel identifies thread type: Red denotes UNC thread. Silver denotes Metric thread. Hoist rings with a UNC securing thread are available in sizes from 800lb to 30,000lb Working Load Limit (WLL). Metric thread types are available in sizes from 400kg to 16,900kg WLL.
180 ° PIVOT
360° ROTATION Fig 31 Hoist Ring
Page 144 of 247
3 2 .7 1. 2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Pr e -u se Swivel hoist rings must be visually inspected before they are used as follows: Check swivel hoist ring unique identification and WLL are present and readable, and colour coded.
3.
Inspect for defect to the threads, corrosion, wear or damage.
4.
Check ring bail for elongation, possible wear, freedom of movement and free rotation through 360°, check pivot moves freely through 180°.
3 2 .8
Sa f e U se
Observe the following: 1. 2.
Check the tapped hole for cleanliness and thread rating Install and tighten to manufacturer’s recommended torque. Make sure the bushing flange meets the load surface.
3.
Do not use spacers between bushing flange and mounting surface.
4.
Do not exceed the swivel hoist ring WLL.
5.
When using lifting slings of two or more legs, ensure that the forces in the legs are calculated using the angle from the vertical to the leg and select the proper size swivel hoist ring to allow for the angular forces.
NOTE: SLING ANGLES MAY DE-RATE SLING MEMBERS (CHAIN, ROPE, OR WEBBING) BUT WILL NOT DE-RATE SWIVEL HOIST RING CAPACITY.
3 2 .9
A f ter Use
Check as for pre-use, return to rigging store and complete ‘returns’ procedure.
Page 145 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
33.0 Beam Clamps A beam clamp is an item of portable lifting equipment, which is used to attach a hoist or similar portable lifting equipment to a structural beam capable of sustaining a load. The onshore/offshore industry uses only the type which actually clamp onto and grip the beam by means of a threaded adjusting bar (see Fig 32). Beam clamps are often used as an anchor point for manually operated hoists. The more common types of beam clamp used in offshore and onshore are shown on Fig 32, they are designed for vertical lifts only and must not be subjected to side loading. Where some side loading is expected to occur in a beam clamp lifting operation, a beam clamp specially designed for side loading shall be used (see Fig 33).
Fig 32 Typical Beam Clamps
3 3 .1 1.
U ni ver sal Sup erc lamp s The only clamp that will accept lateral and longitudinal side loading in line with the beam is the clamp shown in Fig 33. This clamp is suitable for:
2.
Use as an anchor point for lifting and pulling
3.
Loading at any angle (to 90 degrees) without de-rating, both laterally and longitudinally. Low headroom use.
Page 146 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 33 Universal Super clamp
3 3 .2
Pr e -u se I nsp e cti on
Check as follows: 1.
Check beam clamp unique identification, WLL, date of inspection and next inspection due date are present and readable.
2. 3.
Ensure that the adjustable screw rotates freely Inspect for damage, distortion and deterioration, if defects are found the beam clamp must not be used. Report defects and place a notice on the beam clamp indicating that beam clamp must not be used for lifting until defect is rectified.
4.
Generally clean the beam and inspect for damage, defects and deterioration, if any defects are found the beam shall not be used, do not attempt to repair the beam. Report defects to the worksite supervisor.
3 3 .3
B eam Cla mp Sa fe U se
Observe the following: 1.
Do not exceed the WLL of the beam clamp or the WLL of the beam to which the clamp is to be secured.
2.
Ensure that the beam clamp is correctly clamped to the beam and that the centre line of the beam clamp suspension point is in alignment with the centre line of the beam.
3.
Use standard beam clamps for vertical lifts only, no side loading longitudinally along the beam is not permitted.
Page 147 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
4.
Where side loading is expected, use the beam clamps shown in Fig 33.
5.
If two clamps are to be used on a beam for one lift, a spreader bar must be used to ensure equal and vertical loading.
3 3 .4
A f ter U se
Proceed as follows: 1.
Clean the clamp(s) and inspect as for pre-use inspection.
2.
Return clamp(s) to rigging store and carry out ‘returns’ procedure.
Page 148 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
34.0 Beam Trolleys A beam trolley is an item of portable lifting equipment used to attach a hoist or similar portable lifting equipment to a structural beam capable of sustaining the load to be lifted, it also facilitates horizontal movement of the load along the beam. A trolley will be either a 'push' or 'gear' type and can be either permanently fitted, or removable (Fig 34).
Fig 34 Typical Beam Trolleys
3 4 .1
P u s h Typ e Tr ol l ey s
Push type trolleys are generally suited to low suspension levels, light loads (usually 2 tonne maximum) and infrequent use.
3 4 .2
G ea r T ype T r ol l ey s
Gear type trolleys are usually preferred when loads in excess of 2 tonne are handled and/or accurate positioning of the load is required. They are usually traversed by an endless hand chain and are more suited to high suspension levels and regular use.
3 4 .3
B eam Tr ol le y I n sta l l at i on
A Competent Person must carry out the installation of a trolley to a beam. Beam trolleys are in the main adjustable to suit a specific range of beam flange widths. Adjustment is achieved by means of a screwed adjusting bar or by the positioning of spacer washers on the trolley load bar between the side plates. When selecting a trolley, the operating chains (trolley and hoist unit) must be long enough to hang approximately half a metre above the operating level of the load.
Page 149 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
WARNING: BEAM TROLLEYS ARE DESIGNED FOR A VERTICAL LOAD HANDLING ONLY AND ARE NOT SUITABLE FOR SIDE LOADING BEAM END STOPS (TO PREVENT THE TROLLEY RUNNING OFF THE BEAM) MUST BE PRESENT ON ANY BEAM WHERE A TROLLEY IS USED. THE PLATFORM STRUCTURE MUST NOT BE USED TO LIMIT TROLLEY TRAVEL. END STOPS MUST CONTACT THE TROLLEY BODY. TO PREVENT THE TROLLEY MOVING UNDER GRAVITY THE BEAM ON WHICH THE TROLLEY IS USED MUST BE HORIZONTALLY LEVEL UNDER ALL LOADING CONDITIONS.
3 4 .4
A nt i -ti l t Devi ce
Most trolleys are fitted with an anti-tilt device that must be adjusted to just clear the underside of the beam.
3 4 .5
Pr e -u se I nsp e cti on
Check as follows: 1.
Check trolley unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Check cross bolts, side plates and assemblies for security and signs of damage or deterioration; check for distortion of the side plates and/or load bar.
3.
Check bearing stubs and bearings for evidence of wear. (If contaminants penetrate the bearing seals, rapid wear and/or seizure will result).
4.
Check trolley generally for freedom of operation. Check rollers for free running and for any wear at outside diameters.
5.
Where fitted, check hand chain and wheel for deformation and chain links, especially the 'split' link, for distortion. Never attempt to straighten a distorted chain link, it may already have been damaged beyond repair and is unfit for use.
6.
Check also for the possibility of incorrectly substituted components. (Someone may have tried to make one good trolley from two unserviceable trolleys).
7.
Generally clean the beam and inspect for damage, defects and deterioration, if any defects are found the beam shall not be used, do not attempt to repair the beam. Report defects to the worksite supervisor.
8.
Before a trolley is fitted to a beam, ensure that the track width and shape of trolley wheels/rollers is compatible with the beam.
9.
After fitting the trolley to the beam, ensure that trolley centreline is aligned with centreline of the beam web.
10.
Where applicable, check that operating height of hand chain is compatible with beam height.
11. 12.
Confirm that 'end stops' are fitted to the beam. When fitting the trolley to the beam adjust the wheels/rollers so that there is 6 mm clearance overall (i.e. 3 mm max each side between the roller rim and the outer edge of the beam (Fig 35). If the trolley cannot be adjusted to give the required clearance it must not be used.
Page 150 of 247
13.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Function test the trolley without load; run it along the beam. Do not use a trolley that 'sticks', 'slips' or has any form of malfunction. If the hand chain 'jumps' or does not operate smoothly it is not correctly locating in the wheel pockets and the trolley must not be used.
Fig 35
CAUTION:
Beam Trolley Checks
DO NOT OPERATE A TAPPERED SIDE PLATE OR TAPPERED TREAD WHEELED TROLLEY ON A FLAT FLANGE BEAM. DO NOT OPERATE A STRAIGHT SIDE PLATE TROLLEY WITH FLAT TREAD WHEELS ON A TAPPERED FLANGE BEAM
3 4 .6
Sa f e U se
Observe the following: 1.
Do not use the hand chain for lifting or slinging purposes, or for any form of load support.
2.
Do not shock load the trolley and associated equipment.
3.
Do not allow the hand chain to tangle, or to become twisted or kinked.
4.
Ensure that the trolley anti-tilt device is adjusted so that it is just clear of the beam.
5.
Keep the trolley wheels and the beam free of grease and contaminants that may collect foreign bodies, which may then wedge under the trolley wheels.
6.
Ensure that trolley is used for vertical lifts only.
7.
Do not operate a tapered tread wheels on a flat flange beam.
8.
Do not operate a straight tread wheels on a tapered flange beam.
3 4 .7
A f ter Use
Proceed as follows: 1.
Clean the trolley and inspect as pre-use inspection.
2.
Return the trolley to rigging store and carry out ‘returns’ procedure.
Page 151 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
35.0 Plate Clamps Plate clamps are available in two basic designs: 1.
Horizontal Plate Clamps: These are used in pairs and usually suspended by a two-leg sling from a beam. They are intended for lifting and moving metal plate in the horizontal position only.
2.
Universal Plate Clamps: These clamps are intended for lifting and moving metal plate in the vertical position.
Horizontal Plate Clamps
Universal (Vertical) Plate Clamp
Fig 36 Plate Clamps
Selection of a plate clamp for lifting one plate at a time will be subject to three main considerations: 1.
How the plate is to be transported and stacked i.e. horizontally or vertically.
2.
The weight of the plates to be handled, which will determine the WLL of the clamp(s).
3.
The thickness of the plate, which will determine the correct model of clamp with the appropriate jaw opening.
It is important to select a clamp with WLL as close to the weight of the plate (never below) as possible. An over-specified clamp will not be as efficient as one with a WLL just above the weight to be lifted. For lifting more than one plate (in the horizontal position only) specially designed clamps known as Sheet Bundle Clamps must be used (Fig 37).
NOTE: PLATE CLAMPS ARE NOT SUITABLE FOR SUB-SEA WORK.
Page 152 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 37 Example of a Sheet Bundle Clamp
3 5 .1
Pr e -u se
Check the following: Check plate clamp unique identification, WLL, date of inspection and next inspection due date are present and readable.
3 5 .2 1.
H or izo nta l P l at e C la mp s Check plates (to be lifted) and clean off mill scale, grease, paint, or any coating that could prevent the clamp gripping surfaces from making positive contact with the plate.
2.
Inspect clamp cam segment for wear or distortion. Check that the teeth are sharp and free from dirt.
3.
Inspect clamp body for damage, fractures or deformation.
4.
Check clamp opening and closing operation.
5.
Check cam segment shaft and cotter pin for any wear or damage.
6.
Fig 38 shows various acceptable horizontal plate clamp lifting arrangements.
Page 153 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 38
35.3
Horizontal Plate Clamps
Uni ver sa l ( Ve rti cal) Plate Cla mps
1.
Check as for horizontal clamps above, but see also Fig 39
2.
Check operation of locking assembly. Operation must be positive and not heavy or rigid.
3.
Check the lifting eye for wear and/or deformation.
4.
Check operation of the spring by pressing on the hoisting eye in the closed position. This applies force on the spring. The spring must have no signs of corrosion or loss of tension.
Page 154 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 39
3 5 .4
Universal Plate Clamp
Sa fe U se of P lat e Cla mp s
Observe the following: 1.
Horizontal Plate Clamps for carrying plate horizontally. a.
Do not attempt to lift more than one plate at a time.
b.
Always use horizontal plate clamps in pairs
c.
When using multiple pairs of clamps ensure that the load is shared equally between the clamps.
d.
Firmly push the clamp against the plate; if the clamp is fitted with a pretension system no further operation is required. If it does not have a pretension system ensure that the inner side of the clamp body is located against the plate edge when tightening of the clamp occurs.
e.
Ensure equal load on each clamp and that the load is balanced. The clamps must remain positioned against the plate throughout the entire lifting operation. If a gap appears between plate and clamp, lower the plate to a safe position and investigate cause of clamp movement.
f.
When moving plate, take care not to snag or lower the plate onto obstacles or structures, which could cause instability and possibly release the load from the clamps.
g.
Lower plate onto battens to enable removal of clamps, never use the hoist to remove clamps.
2.
Universal (Vertical) clamps for carrying plate vertically a.
Clamp plates used to carry plate vertically are also suitable for lifting and turning steel plates.
b.
Determine the weight and size of the plate to be lifted. This will determine the WLL and type of clamp to be used.
c.
These clamps are used to lift, turn or transfer only one plate at any one time.
Page 155 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
d.
Vertical clamps can be used individually, in pairs, or in multiples.
e.
When using more than one clamp ensure clamps are equally loaded.
f.
in the open position onto the plate so that the jaw of the clamp rests completely on the plate, and then set the locking assembly to the ‘LOCK’ position.
g.
Before lifting, check the clamp to ensure that it is locked onto the plate.
h.
When using two clamps to lift a plate, a spreader bar must be used to prevent overloading the clamp and slippage due to angle increase (see fig 38). Reference shall be made to manufacturers safe working load charts with respect to clamps used at angles, especially when used with endless chain slings.
i.
When lowering the load, lower the hoist sufficient to enable a complete disengagement of that the plate is adequately supported and cannot slip and that the lifting sling is loose enough for the clamp to be removed.
j.
To minimise damage of the cam segment when not in use leave clamp in an open position.
CAUTION UNIVERSAL PLATE CLAMPS CAN LIFT A PLATE FROM HORIZONTAL TO VERTICAL AND VISA-VERSA, BUT MUST NOT BE USED TO TRANSPORT PLATES HORIZONTALLY. DO NOT USE PLATE CLAMPS FOR THE PURPOSE OF TRANSFERING STEEL PLATE AROUND THE PLATFORM/PLANT. THE USE OF THIS TYPE OF LIFTING APPLIANCE IS RESTRICTED TO SITUATIONS WHERE PLATE IS BEING REMOVED FROM A RACKING SYSTEM, OR IS BEING MOVED SHORT DISTANCES WHERE THE PLATE CAN BE RETAINED JUST ABOVE THE DECK/GROUND. PLATE CLAMPS SHALL NOT BE USED IN CONNECTION WITH LIFTING OPERATIONS USING OFFSHORE CRANES.
Page 156 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
36.0 Rigging Screws / Turnbuckles The terms `rigging screw' and `turnbuckle' are often applied to a piece of rigging equipment, which, through the use of screw threads, provides a means of length adjustment or tensioning in a secured rope. There are differences however, between a rigging screw and a turnbuckle. A rigging screw consists of a tubular (closed) body sometimes referred to as a box or bottle with a screwed fitting each end (see Fig 40). View Holes
Fig 40 Rigging Screw
A turnbuckle consists of two reins with a boss at each end (open body) with a screwed fitting each end (see Fig 41).
Fig 41
Turnbuckle
In each case, the body is internally threaded, one end with a right hand thread and the other end with a left-hand thread. Rotating the body of the unit will thus either increases or decreases the overall length of the screw assembly. The length of the body dictates the amount of adjustability (more commonly known as `Take-up'). In the interests of safety, open bodied screws are preferred. With closed body screws, there is a possibility of `over-opening' and consequent failure due to lack of load bearing thread. When closed rigging screws are used they must be fitted with view holes (refer to fig 40). When in use, the threads must not be screwed beyond these holes to prevent inadvertent over opening. Within SMEP, these items are classified as ‘lifting equipment’ and must have certification. However, they shall not be used for lifting purposes. Rigging screws and turnbuckles are normally supplied in a galvanised condition with a variety of end fittings as illustrated in Fig 42. It is recommended that once the ideal length required has been calculated, a screw shall be selected which meets this dimension at `Mid-position' to allow adjustment in each direction.
3 6 .1
Pr e- u se
Check as follows: 1.
Check rigging screw/turnbuckle unique identification, WLL, date of inspection and next inspection due date are present and readable
Page 157 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
2.
Check for thread damage, stretch and possibility of a bent thread bar.
3.
Check for cracks or distortion to body (Fig 42).
4.
Check for cracks or distortion to both end fittings, especially at the neck of the shank.
Jaw
Hook Note: the hook has reduced capacity
Eye
Fig 42 Turnbuckle Inspection
3 6 .2
Sa f e U se
Observe the following: 1.
Select the correct type and size for the job. (Thread size determines SWL). Refer to Manufacturer’s load charts.
2.
If a turnbuckle is to be used in an application where vibration is present, the end fittings shall be secured with locking nuts wire to prevent loosening alternatively it may be secured with locking wire to prevent loosening (Fig 43).
3.
If the rigging screws/turnbuckles are to be used in an environment where vibration is present, it shall be specified that they are fitted with locking wire or split pins, lock nuts can be used but they may slacken.
Page 158 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
FIT LOCKING WIRE AT EACH END TO PREVENT SCREW TURNING
Fig 43 4.
Locking Wire Fitted to Turnbuckle
If a rigging screw is used with hook end fittings a reduction in working load limit will be required. (Refer to Manufacturer’s load charts).
5.
Never over tighten rigging screws/turnbuckles.
Page 159 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
37.0 Wedge and Socket Wedge and socket assemblies are usually encountered as terminations on crane running ropes. Fig 44a, b and c show the assembly arrangement of a typical wedge and socket arrangement.
Fig 44a
Wedge and Socket Arrangement
Fig 44b Terminator wedge and socket arrangement
Page 160 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Wrong Rope backwards
Wrong Wedge Backwards
Wrong Dead end clamped to live end
Correct
Fig 44c Termination of the Crosby “Terminator” Wedge and Socket
*Wedge and Socket Tail Length Standard 6 to 8 strand wire rope
Rotation Resistant Wire Rope
A minimum of 6 rope diameters, but not less than 152 mm (6")
A minimum of 20 rope diameters, but not less than 152 mm (6"). Table 1
Rope Size
(10 mm)
(13 mm)
(16 mm)
(19 mm)
(22 mm)
(25 mm)
(29 mm)
(32 mm)
3/8”
½”
5/8”
¾”
7/8”
1”
1-1/8”
1-1/4”
Clip Size
(10 mm)
(13 mm)
(16 mm)
(19 mm)
(22 mm)
(25 mm)
(29 mm)
(32 mm)
3/8”
½”
5/8”
¾”
7/8”
1”
1-1/8”
1-1/4”
*Torque Ft./lbs.
45
65
95
130
225
225
225
360
* The tightening torque values shown are based upon the threads being clean, dry, and free of lubrication. Table 2
3 7 .1
Pr e -u se
Check the following: 1.
Check the wedge and socket unique identification, WLL and rope size are present and readable.
2.
Check that the wedge/socket are the correct size for the rope.
3.
Check the dead end of the rope length (Table 1). Ensure rope grip is secure. Accidental slackening of the rope grip could slacken the rope and dislodge the wedge, resulting in the wedge dropping out.
4.
Check the rope around the wedge for corrosion and security.
5.
Check for signs of cracking/distortion on the socket body.
Page 161 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3 7 .2 1.
Sa f e U se If the wedge and socket is to remain in use, periodic inspection and renewal of the termination must be carried out throughout the life of the rope. a.
After installation, a good covering of grease must be applied at the bend as protection against weather.
Page 162 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
38.0 Lifting Nipples and Lifting Caps Lifting nipples and lifting caps shall be certified and approved for lifting.
3 8 .1
Pr e -U se
Before use, a check shall always be carried out to: Ensure that the thread section on the pipe and on the lifting nipple or lifting cap are undamaged
3 8 .2 1.
Sa f e U se The lifting nipple or lifting cap is correctly installed, and that the thread dimension and type are the same.
2.
When moving a load with lifting nipple or lifting cap, the area below the travel path is barred off.
Page 163 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
39.0 Runway Beams Runway beams are specially fitted beams, or structural beams that have been tested and certified for lifting purposes and the attachment of items of lifting equipment. Three basic types of runway beam are found on offshore platforms (Fig 45). 1.
Rolled Steel Joists (RSJs)
2.
"I" or "H" Beams
3.
Universal Beams
RSJ UNIVERSAL BEAM
I or H
Centre line of suspension point must always align with centre line of beam/column Fig 45 Types of Runway Beam
3 9 .1
B eam Id e nt ity
Certified runway beams must have: 1.
Unique identification, SWL, date of inspection and next inspection due date are present and readable Identification marking (Fig 46).
2.
Zebra striping to indicate they are runway beams and to improve visibility.
The striping must: a.
Be at an angle 30-60 degrees to the horizontal;
b.
Be 40-150 mm wide; and
c.
Consist of two contrasting colours, yellow and black.
Black Yellow Fig 46 Beam Identity
Page 164 of 247
3 9 .2
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
U ncer ti fied Li ftin g Beams
If a section of the platform structure is to be used for lifting purposes but is not certified for lifting, a risk assessment must be carried out and a lifting plan prepared Refer to section 8 for details. The lifting plan together with a sketch, details of the item to be lifted and the lifting equipment etc must be forwarded to the appropriate Asset Structural Engineer for approval.
CAUTION UNDER NO CIRCUMSTANCES SHALL PIPEWORK BE USED TO SUPPORT ANY PIECE OF LIFTING EQUIPMENT.
3 9 .3
Pr e -u se I nsp e cti on
Before using a runway beam the following checks must be carried out: 1.
Check beam unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Confirm that the total load to be suspended from the beam will not exceed the beam WLL.
3.
Generally clean the beam and inspect for damage, defects and deterioration, if any defects are found the beam shall not be used, do not attempt to repair the beam. Report defects to the PIC and worksite supervisor.
4.
Where a beam is bolted to the supporting structure ensure that all bolts/nuts are secure and in good condition.
5.
Check, where appropriate, that end stops are fitted to the beam and are adequate to prevent a travelling lifting device running off the beam. The platform structure must not be used to stop a travelling lifting device fitted to a beam
.
Fig 47
Runway Beam Inspection
Page 165 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3 9 .4
Sa f e U se
Observe the following: 1.
No more than one item of lifting equipment shall be used on the same runway beam at the same time.
2.
With a cantilever runway beam extra care must be taken when operating at, or near, the beam SWL and at the extreme end of the beam.
3.
Do not: a.
Attach additional steelwork or suspend scaffold pipes, cables etc from runway beams.
b.
Shock or side load runway beams.
Page 166 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
40.0 Lifting Points A ‘Lifting Point’ is generic term for the ‘certified’ point(s) or attachment(s) on an item of plant, by which it can be safely lifted. The term also applies to points or attachments fixed to structural members and from which a load can be suspended. For example lifting lugs, lifting eyes, trunnions, fabricated lifting plates, pad eyes.
4 0 .1
Pa de ye s
Pad eyes are lifting eyes that have been attached (welded or bolted) to a beam, structure or similar to be used for lifting purposes. Padeyes shall be identifiable at point of location with the padeye centrally positioned in a 20 cm x 20 cm painted square (minimum size). The square shall be painted with zebra striping. The striping must: 1.
Be at an angle 30-60 degrees to the horizontal.
2.
Be 40-60 mm wide.
3.
Consist of two contrasting colours, yellow and black.
WARNING: A PAD EYE IS DESIGNED AND CERTIFIED FOR VERTICAL LIFTS ONLY. HOWEVER, A SUITABLY SUPPORT WELDED PAD EYE (FIG 48) CAN BE USED FOR LIFTS AT ANGLES UP TO 45° PROVIDED THAT A RISK ASSESSMENT IS CARRIED OUT BY A ‘COMPETENT PERSON’. WHEN ASSESSING LOAD WEIGHT ON THE PAD EYE, INCLUDE WEIGHT OF LIFTING EQUIPMENT AND SLINGS, OR ADD 10% TO TOTAL IF WEIGHTS ARE ESTIMATED.
Visually check the state of the weld Zebra striping
Check condition of padeye in general and hole for elongation or damage Padeye identity and SWL (Padeye shall not be used if no identity or SWL is displayed!) Fig
48 Typical Pad Eye Welded to Beam
Page 167 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 49 Pad Eye - Bolt-on Type
4 0 .2
B ol t- o n Pa d Eye s
Bolted-on pad eye type lifting points suitable for the fitting of shackles through which lifting equipment can be attached are shown on Fig 49.
4 0 .3
Pr e -u se I nsp e cti on
Check as follows: 1.
Check pad eye unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Clean the pad eye and immediate vicinity, inspect for damage, distortion and deterioration, if defects are found the pad eye must not be used. Report defects and place a notice on the beam indicating that padeye must not be used for lifting until defect is rectified. Padeyes with flame cut holes are not suitable for lifting purposes and therefore shall not be used.
4 0 .4
Sa f e U se
Observe the following: 1.
A pad eye is designed and certified for vertical lifts only. However, a suitably support welded pad eye (Fig 48) can be used for lifts at angles up to 45° provided that a risk assessment is carried out by a ‘competent person’ and suitable de-rating is applied.
2.
Whenever lifting equipment is attached to a pad eye, a shackle must be fitted between the pad eye and the equipment in the correct manner as shown in Fig 50.
Page 168 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 50 Fitting a Shackle to a Pad Eye
4 0 .5
O t her Types o f Li f ti ng P oi nt s
Other types of lifting points that may be encountered on equipment to be lifted, and which can be used if a risk assessment is carried out, are listed below: 1.
Holes inherent in the design, suitable for shackles.
2.
Trunnions.
3
Welded-on integral pads for jacking points.
4.
Links welded on to reinforcing members in a concrete structure.
5.
All integrated lifting points that are cast into concrete beams or blocks must be of a propriety type, which have the necessary certification supplied. Under no circumstances shall high tensile reinforcing bar be used as or made into lifting points.
4 0 .6
A dd iti ona l L i fti n g P oi nt s
If additional lifting points have been secured to a lifting beam, the following points must also be present: 1.
2.
Each additional lifting point shall be clearly and permanently marked with: a.
Identification (serial) number.
b.
Safe Working Load at 0° to 90°.
c.
Inspection date and next due date.
Tapped holes, when used to locate a lifting point (e.g. eye bolt), shall have the thread form and diameter permanently marked adjacent to each hole.
Page 169 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
When equipment forms part of a larger assembly, a list of the assembled parts, their individual weights, and the total assembled weight shall be given on a clearly visible tally plate, e.g.:
P la nt wei gh t s
P u mp
2 .6t e
Motor
1 .8te
B a se Pla te
0 .9t e
T ota l A s semb ly
5 .3t e
Any possible load supporting arrangement (e.g. a hole in the beam) which cannot be used safely, and is accessible such that casual use could occur, shall be identified and tagged, ‘NOT SUITABLE FOR LIFTING’.
Page 170 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
41.0 Spreader Beams and Lifting Frames Spreader beams and lifting frames are often specially made to facilitate a particular ‘lift’. A certificate of test and examination shall be supplied with each spreader beam and associated equipment, or lifting frame. The certificate of test and examination will refer to all associated equipment, e.g. those covering the shackles, hooks etc, and the Non-destructive Examination (NDE) reports. Refer to Section 3.0
Page 171 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
42.0 Manually-Operated Hoists 4 2 .1
R a t ch e t Lev e r Bl ock s ( Pu l l Lif t s or C h a i n L e v e r H oi s t)
A ratchet lever block is a lifting machine, which, through the use of a gearbox and brake mechanism, allows the user to raise heavy loads (commonly up to 6 tonne) by applying a force to the operating lever. Typical examples are shown at Fig 51 ratchet lever block with capacities up to 15 tonne are manufactured.
Fig 51 Typical Ratchet Lever Block Ratchet lever block can be operated at any angle, including upside down. They are available with two types of chain i.e. standard short link chain and roller chain (Fig 52). Link chain models are the most popular as they are flexible and easy to use whereas roller chain models tend to be more rigid and the chains corrode and seize more readily. Some manufacturers of this type of ratchet lever block have a pawl release lever that when manually operated release the hoist pawl and allows the load chain to be pulled freely through the machine, by hand, in either direction.
Fig 52 Ratchet Lever Block with Pawl
Page 172 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
WARNING: ON RATCHET LEVER-BLOCKS/PULL LIFTS WITH MANUAL RELEASE PAWL, THE PAWL MUST NOT BE DISENGAGED WHEN THERE IS A LOAD ON THE HOOK, OR THE LOAD WILL DROP. RATCHET LEVER-BLOCKS/PULL LIFTS THAT HAVE UN-COATED ALUMINIUM COMPONENTS IN THEIR CONSTRUCTION ARE UNSUITABLE FOR USE IN AN OFFSHORE ENVIRONMENT. An advantage when using a ratchet lever block instead of a chain block is the ‘drawn up dimension' (closed height) where headroom may be limited. A disadvantage with ratchet lever block is that to operate the ratchet lever block, the user must be at the same level as the suspension point, which could create a problem, if access to the hoist suspension level is restricted. Non-spark ratchet lever block are available for use in hazardous areas and pull lifts can also be supplied specially coated for use in an offshore environment. Most ratchet lever blocks are suitable for sub-sea work but not all. Consult the manufacturers for confirmation of suitability before using a ratchet lever block for sub-sea lifting. The design of ratchet lever block is such that a brake mechanism is used to suspend the load. This brake mechanism gives the lever hoist its versatility but also introduces limitations on its use. The brake relies on the load tension for its operation, so the block requires a weight or tension on the load chain before the brake mechanism will function and securely hold the load. Under very light load conditions, lever hoists have been known to pay out chain due to the lack of load on the brake. This has been a particular problem when, or immediately following, changing the hoisting direction from up to down or vice versa. When planning a lifting operation using a lever hoist or selecting a lever hoist for a lift, the light load limitation of the braking mechanism should be recognised and the hoist should not be used to lift a load that is less than 10% of the stated working load limit for that hoist.
WARNING: THE RATCHET LEVER BLOCK/PULLIFT MACHINE IS DESIGNED FOR ONE-MAN OPERATION. DO NOT FIT A HANDLE EXTENSION, USE TWO-MAN OPERATION, OR USE ANY EXCESSIVE FORCE TO OPERATE THE HOIST. THE MINIMUM LOAD LIFTED SHOULD NEVER BE LESS THAN 10% OF THE SWL AT NO TIME DURING LIFTING OPERATIONS SHOULD THE WORKING LOAD LIMIT OF A RATCHET LEVER BLOCK BE EXCEEDED. A RATCHET LEVER BLOCK/PULLIFT MUST NOT BE IN A DYNAMIC LIFTING ARRANGEMENT WHERE THE LOAD ON THE BRAKE VARIES, E.G. AS THE LOAD GOES THROUGH THE SPLASH ZONE.
4 2 .2
Pr e -u se
The following checks must be carried after ‘booking out’ from a rigging store and before use. If the ratchet lever block fails any one of the following checks it must be rejected: 1.
Check hoist for unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Where fitted, check that the pawl operates correctly, in raising, lowering (engaged) and 'pull through' (disengaged) modes of operation. When engaged the pawl gives a distinctive 'clicking' sound when the ratchet lever block is operated.
Page 173 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check chain, load wheel and chain end stop. To prevent the end of the chain from passing through ratchet lever block, an end stop must be present on the free end of the load chain.
4.
Hang the ratchet lever block on its suspension hook and pull the load chain out to its 'stop' and let it hang vertically free. The chain linkage must all appear to be in a straight line, if the chain gives the appearance of having a 'spiral' the ratchet lever block has been overloaded whilst the chain was twisted. There must be no damaged, corroded or distorted components (Fig 53).
5.
Check for build-up of dirt in the pocket wheel.
6.
Check correct operation of selection lever.
7.
Check the suspension hook and load hook. Ensure hook safety latch functions correctly and the swivel operates without restriction. Check also for obvious opening-out, of either the load hook or the suspension hook.
8.
Check load chain for distortion, corrosion and any other form of damage.
9.
If the hoist has not been used for some time the load chain could be dry, spray with light machine oil.
Fig 53
4 2 .3
Ratchet Lever Block Pre-use Checks
Sa f e U se
Observe the following: 1.
On a hoist with a pawl release lever, ensure that the pawl release lever is in the 'engaged' position before operating the hoist (Fig 54).
2.
The pawl must not be disengaged whilst there is a load on the hoist hook or the load will drop!
Page 174 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
3.
Do not use load chain for slinging purposes (Fig 55).
4.
Do not twist or knot the load chain.
Fig 54 Ratchet Lever Block Pawl
Fig 55 Incorrect Use of Load Chain and Correct Slinging Method 5.
Ensure that the suspension point to which the hoist is to be attached is approved and is of adequate capacity for the load to be lifted.
6.
Before applying full load, to hoist, check that: a.
The load will not drop if hand lever is released. Check by selecting ‘Raise’ and operating hand lever to take the weight of load, and then releasing hold on hand lever.
b. 7
Select 'Lower' and repeat (a) to check for slip/drop when lowering.
When operating the ratchet lever block ensure that the ratchet lever block operates smoothly and easily and with a distinctive ratchet 'clicking' sound. If it requires
Page 175 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
excessive force to operate the ratchet lever block, stop lifting operations and investigate, a ratchet lever block must always operate smoothly and easily; it is designed for one-man operation. Do not: a.
Use a handle extension.
b.
Apply excessive force.
c.
Operate by two persons.
If operation of the hand lever is difficult - something is wrong! 7.
The ratchet lever block is much more versatile than a chain block, as it can be used in almost any orientation. It is important, however, that the free end chain runs smoothly through the block without ‘hanging up’. When the ratchet lever block is used in an inverted orientation it is possible for the free end chain to bunch up, jam temporarily then release unexpectedly if not fed through cleanly. It is therefore not recommended that ratchet lever blocks be used fully inverted and that attention is paid to how the chain runs through the block when partly inverted.
8.
Where a ratchet lever block introduces a single point failure into a lifting arrangement, the user must consider the use of static rigging or some other means to eliminate the potential single point failure. This is particularly important if a load is to be suspended on a ratchet lever block for an extended period. The need for additional backup rigging must be identified as part of the lift plan and risk assessment. As an alternative to static rigging, consideration can be given to the use of a suitably rated mechanical stopper fitted in place of the end stop that is capable of being moved up and down and attached to the free end chain such that it can be positioned close to the body of the ratchet lever block – like a movable end stop. Any modification e.g. brake friction material or chain end stop should be discussed with the manufacturer. If the brake mechanism fails the chain could only run through the hoist until the mechanical stopper contacts the ratchet lever block body, significantly limiting the distance the load can drop.
9.
When a load is removed from a ratchet lever block other than by the use of the ratchet lever block (e.g. by transfer of a load to a crane) the brake mechanism will remain locked together. Subsequent loading of the hoist (for example, by the transferring of a load on to the block from a crane) will result in the load being applied to a locked brake mechanism – something manufacturers regard as bad practice, potentially resulting in unexpected slippage as the block is then operated. If a ratchet lever block has the load transferred off it (a common practice during sub-sea use) the block must be operated to unlock the brake and confirm the block is fully functional before a load is transferred back on to it. Alternatively the load can be landed (or suspended on static rigging) by using the ratchet lever block before the transfer to the other lifting device.
10.
When using multiple ratchet lever blocks, each individual block must be rated to a capacity of at least 100% of the load. If two or more ratchet lever blocks are used to share the load during lifting operations, careful consideration of the operation is
Page 176 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
necessary as there is the potential to overload one of the blocks (beyond the working load limit) or under load one of the blocks (below 10% of the working load limit). 11.
If the application requires the load to be supported for a significant length of time between the lifting and lowering operations, consideration should be given to using other equipment to sustain the load, as the block may corrode during the supporting period and be unsafe for the subsequent lifting or lowering part of the operation.
12.
Contamination of the brake lining can also cause the ratchet lever block to fail. This can be due to inappropriate cleaning practices, e.g. using a pressure washer or immersion in diesel, or because of in-water contamination.
4 2 .4
A f ter U se
Check as follows: 1.
Thoroughly clean the ratchet lever block, remove any rubbish, which may have become attached to the chain preservative, and check generally for abnormalities.
2. 3.
Secure lifting chain to avoid chain lying on ground when hoist is hung in rigging store. Spray load hook and chain with light machine oil. Take care not to contaminate clutch mechanism.
4.
4 2 .5 1.
Return the ratchet lever block to rigging store and complete ‘returns’ procedures.
R a t ch e t Lev e r Bl ock s i n a n Off s h ore S ub -Sea E nv iro nme nt As with any item of lifting equipment, the ratchet lever block will be specified for a maximum working load limit. This should not be exceeded during any lifting operation. It is important, therefore, when planning an underwater lifting operation that the load to be lifted on the block is known or has been accurately estimated with an adequate allowance for safety. The possible effects of additional loading, such as friction, seabed suction and buoyancy, should be included when the ratchet lever block is being selected for the lift.
2.
The ratchet lever block is intended for straight line static lifting. If used in a dynamic lifting arrangement, the changing loading may cause the block to fail or slip. As the load goes through the splash zone the weight could come off the brake mechanism and the chain could run out. Ratchet lever blocks are not suitable for use in over-board rigging and must not be used in a dynamic lifting application.
3.
During use, care must be taken to avoid needlessly contaminating the ratchet lever block brake mechanism, such as by dragging it along the seabed.
4.
Extended periods in salt water and cyclic periods of immersion may accelerate the corrosion of the internal components in the ratchet lever block. Practices such as using ratchet lever blocks in the splash zone and continually subjecting them to salt water and then air will accelerate corrosion and will affect the ability of the block to hold a load in a short period of time. The prevention of accelerated corrosion leading to slippage/failure to hold the load can best be reduced by where the ratchet lever blocks are only used sub-sea once before being inspected, serviced and retested. Each ratchet lever block must only be submerged once and this immersion shall have a specified
Page 177 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
maximum time limit. A ratchet lever block must not be submerged a second time until it has been inspected, serviced and tested by a suitably qualified person.
4 2 .6
H and -Op era ted Cha i n B l o ck s
A manual chain hoist or chain block is a lifting machine, which, through the use of a gearbox and brake mechanism, allows the user to raise heavy loads (capacities up to 50 tonnes) by applying a force to the operating chain (hand chain). A typical chain block is shown at Fig 56. A Chain block performs a similar function to the ratchet lever block but has distinct design differences: 1.
It has an endless hand chain that operates the lifting and lowering functions.
2.
It has a dedicated load chain terminating with a safety hook.
3.
A chain block has an automatic brake mechanism that is capable of arresting and sustaining a load to the WLL of the unit.
4.
A chain block has a ratchet wheel and a spring-loaded pawl. Design is such that the pawl will operate irrespective of wear in any part of the brake assembly, but may not operate effectively if the chain block is used out of vertical.
5.
It is not uncommon for loads to be pulled horizontally during rigging operations, however, it must be remembered that there is an increase loading effect on the chain block with horizontal movement of the load e.g. If a 1 tonne load is pulled 45 degrees from the vertical, the load on the chain block will increase 1.5 tonne.
Fig 56 Typical Chain Block Assembly
WARNING: CHAIN BLOCKS THAT HAVE UN-COATED ALUMINIUM COMPONENTS CONSTRUCTION ARE UNSUITABLE FOR USE IN AN OFFSHORE ENVIRONMENT.
Page 178 of 247
IN
THEIR
4 2 .7
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
C ha i n Bl o ck U sage Termi nol og y
Commonly used chain block terminology is shown at Fig 57.
Fig 57 Chain Block Terminology
A major consideration when selecting a chain block is the ‘drawn up dimension' (closed height) due to the lack of headroom in offshore modules. This dimension varies with different manufacturers and different configurations.
4 2 .8
Var i ou s Typ e s of Chai n B l ock
Standard chain blocks are supplied with swivelling top and bottom hooks for ease of attachment to suspension point and load. They can be hooked into a beam trolley for travelling along a runway beam or can be supplied `built-in' to a trolley to save headroom. Where clearance between runway beam and load is particularly restrictive, Ultra-low headroom trolley hoists can be utilised.
42.9
Chain Bl ock Sa f ety Considerations
Chain blocks are primarily designed to operate vertically.
WARNING: THE PAWL OF A CHAIN BLOCK MAY NOT OPERATE EFFECTIVELY IF THE CHAIN BLOCK IS USED ‘OUT OF VERTICAL’. THUS CHAIN BLOCKS SHALL BE USED FOR VERTICAL LIFTS ONLY. IF A CHAIN BLOCK IS REQUIRED FOR USE ‘OUT OF VERTICAL’ THE PERSON IN CHARGE MUST BE CONSULTED, BEFORE SUCH A LIFT IS UNDERTAKEN. THE MINIMUM LOAD LIFTED SHOULD NEVER BE LESS THAN 10% OF THE SWL.
Page 179 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
THE CHAIN BLOCK IS DESIGNED FOR ONE-MAN OPERATION. DO NOT, USE TWO-MAN OPERATION, OR USE ANY EXCESSIVE FORCE TO OPERATE THE BLOCK. AT NO TIME DURING LIFTING OPERATIONS SHOULD THE WORKING LOAD LIMIT OF A CHAIN BLOCK BE EXCEEDED. A CHAIN BLOCK MUST NOT BE IN A DYNAMIC LIFTING ARRANGEMENT WHERE THE LOAD ON THE BRAKE VARIES, E.G. AS THE LOAD GOES THROUGH THE SPLASH ZONE. Non-spark chain blocks are available for use in hazardous areas, and they can also be supplied specially coated for use in an offshore environment. Most chain blocks are suitable for sub-sea work. However, the brake material used in some models will preclude sub-sea use and the manufacturer must be contacted for confirmation of suitability before a unit is used sub-sea.
4 2 .10
Pr e -u se
The following checks must be carried out before use, if the chain blocks fail any one of the following checks it must be rejected: 1.
Check chain block unique identification, WLL, date of inspection and next inspection due date are present and readable (Fig 58).
2.
Check load chain for bent, stretched or corroded links.
Fig 58 Chain Block Inspection
3.
Check hand and load chain pocket wheels are in good order and free from debris.
4.
Check body assembly for damage.
5.
Suspension and load hook safety latches must function correctly and swivels operate without restriction. Ensure that there is no obvious opening-out of the hook(s).
Page 180 of 247
6.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check load chain for distortion, corrosion and any other form of damage. Never attempt to straighten a distorted chain link. A distorted link may have been already be damaged beyond repair and will be unfit for use.
7.
If the hoist has not been used for some time, the load chain may be dry and must be spray coated with light machine oil. Take care not to contaminate brake mechanism. The chain must not however, be over-lubricated as contamination of the hoist brake discs could result.
8.
If visible, check ratchet pawl and ratchet wheel for correct operation, damage and distortion. Similarly check for damage and distortion to any other visible mechanisms.
4 2 .11
Sa f e U se
Observe the following: 1.
Do not use the chain block load chain for slinging purposes, or make any modification to the way in which the chain block was designed to be used.
2.
Ensure chain block load chain and the hand chain are of adequate length for the proposed lifting operation and the load hook has adequate range of lift.
3.
A chain block must be used for vertical lifts only. The pawl of a chain block may not operate correctly if the chain block is used out of the vertical.
4.
Do not attempt to operate the chain block beyond the maximum specified range. It is possible to impose excessive load on the chain anchor when the bottom hook is at its lowest position.
5.
When using a hook suspended chain block, ensure that the chain block hook can move freely and unhindered in the eye of the attachment point.
6.
After attachment, ensure that the load chain and hand chain hang freely and where a bottom hook block is reeved with two falls ensure that the block has not 'turned-over' and the chain is not twisted.
7.
If the lifting operation involves lifting light loads with long load chains be aware that the chain slack may be heavier than the load and cause a 'run-back' resulting in lowering the load.
Page 181 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 59 Excessive Force on Chain Block Hand Chain 8.
Chain blocks are designed for one-man operation, without excessive force.
9.
Do not allow dirt or grease to accumulate in the profiles of the hand or load chain wheels.
10.
If the load chain 'jumps' or does not operate smoothly it may not be sitting properly in the pocket wheel. This type of fault is more common on chain blocks with two or more falls where a load hook may have become ’turned over’, twisting the chain. If this is the case the block can be ‘flipped back’ to eliminate a twist in the falls. If after flipping back, the load chain still ‘jumps’ the chain may have been stretched, or there is damage to the pocket wheel, in either case the block must not be used.
11.
Listen for the 'clicking' of the ratchet pawl during use. The absence of the ratchet 'clicking' noise will indicate a malfunction in the chain block mechanism.
12.
Within its designed operating range, a chain block must operate easily and smoothly with one person on the hand chain. If excessive force is required on the hand chain to lift a rated load, stop the operation and investigate.
13.
Ensure that shock loads are not imposed on the chain block through too vigorous operation of the hand chain.
13.
If a chain block is accidentally dropped, it must not be used. Return for examination/overhaul.
14.
Where a chain block introduces a single point failure into a lifting arrangement, the user must consider the use of static rigging or some other means to eliminate the potential single point failure. This is particularly important if a load is to be suspended on a chain block for an extended period. The need for additional backup rigging must be identified as part of the lift plan and risk assessment.
15.
When using multiple chain blocks, each individual block must be rated to a capacity of at least 100% of the load. If two or more chain blocks are used to share the load during lifting operations, careful consideration of the operation is necessary as there
Page 182 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
is the potential to overload one of the blocks (beyond the working load limit) or under load one of the blocks (below 10% of the working load limit). 16.
If the application requires the load to be supported for a significant length of time between the lifting and lowering operations, consideration should be given to using other equipment to sustain the load, as the block may corrode during the supporting period and be unsafe for the subsequent lifting or lowering part of the operation.
17.
Contamination of the brake lining can also cause the chain block to fail. This can be due to inappropriate cleaning practices, e.g. using a pressure washer or immersion in diesel, or because of in-water contamination.
4 2 .12
A f ter Use
Proceed as follows: 1.
After use, the chain block must be cleaned and inspected following the same procedure used for Pre-use inspection. Do not jet wash with water as this will penetrate and corrode internal mechanisms. Do not allow oil, grease or other substances to contaminate brake discs. A defective chain block must not be used, it must be sent for overhaul.
Fig 60 Chain Block Storage 2.
Carefully lubricate a chain hoist; excessive or careless lubrication may lead to the lubricant penetrating the brake, which could then fail under load.
3.
When storing a chain block, lubricate and 'wrap' the chains (Fig 60).
4.
Return chain block to rigging store and complete ‘returns’ procedures.
CAUTION MANUAL OR POWERED OVERHEAD HOISTS SHALL NOT BE USED FOR LIFTING PERSONNEL
Page 183 of 247
4 2 .13 1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
M an ua l C hai n Bl o ck s i n a n Off s ho re S ub- Sea Envir onme nt As with any item of lifting equipment, the chain block will be specified for a maximum working load limit. This should not be exceeded during any lifting operation. It is important, therefore, when planning an underwater lifting operation that the load to be lifted on the block is known or has been accurately estimated with an adequate allowance for safety. The possible effects of additional loading, such as friction, seabed suction and buoyancy, should be included when the chain block is being selected for the lift.
2.
The chain block is intended for straight line static lifting. If used in a dynamic lifting arrangement, the changing loading may cause the block to fail or slip. As the load goes through the splash zone the weight could come off the brake mechanism and the chain could run out. Manual chain blocks are not suitable for use in over-board rigging and must not be used in a dynamic lifting application.
3.
During use, care must be taken to avoid needlessly contaminating the chain block brake mechanism.
4.
Extended periods in salt water and cyclic periods of immersion may accelerate the corrosion of the internal components in the ratchet lever block. Practices such as using ratchet lever blocks in the splash zone and continually subjecting them to salt water and then air will accelerate corrosion and will affect the ability of the block to hold a load in a short period of time. The prevention of accelerated corrosion leading to slippage/failure to hold the load can best be reduced by where the ratchet lever blocks are only used sub-sea once before being inspected, serviced and retested. Each ratchet lever block must only be submerged once and this immersion shall have a specified maximum time limit. A ratchet lever block must not be submerged a second time until it has been inspected, serviced and tested by a suitably qualified person.
Page 184 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
43.0 Powered Chain Hoists 4 3 .1
P ne u mati c Chai n H oists
Most powered chain hoists used in the hydrocarbon industry are pneumatically operated. The main safety feature built into this type of hoist is that the brakes are spring-loaded to the “ON” position and require air pressure for release. In the event there is a loss of pneumatic power (e.g. a burst hose) the brake automatically applies to prevent the load from falling (fail safe). Most hoists are also fitted with trip devices to prevent over-hoisting or over-lowering. The standard range of lift is 3 metres but this can be increased to suit any specific requirement. If a substantial increase is required, the manufacturer must be consulted, as it may be necessary to de-rate the hoist due to the excess weight of load chain. For chain hoists fitted with long load chains, a chain collector boxes can be fitted to the hoist. The hoist control pendant or chains normally hang 1 metre above the lowest position of the bottom hook. Pendant controls (with push buttons) are the preferred option but can stick when exposed to a contaminated air supply. Standard pneumatic hoists are usually supplied with a swivelling top and bottom hooks for ease of attachment to suspension point and load. They can be hooked to a beam trolley for travelling along a runway beam or can be supplied with a ‘built-in' trolley to save headroom. Pneumatically powered hoists are primarily designed to lift loads vertically but hook suspended blocks will work efficiently up to 45% off the vertical.
WARNING: PNEUMATIC CHAIN HOISTS HOOKED TO, OR BUILT INTO TROLLEYS (OR COMBINED UNITS) MUST BE USED FOR VERTICAL LIFTS ONLY. PNEUMATIC CHAIN HOISTS ARE NOT SUITABLE FOR SUB-SEA WORK. Pneumatically powered hoists that have un-coated aluminium components in their construction are unsuitable for use in an offshore environment they can however be supplied specially coated for use in an offshore environment. Non-spark models are available for use in hazardous areas.
4 3 .2
El ec tr ica lly P ow ered Chai n H oi st s
The main safety feature built into this type of hoist is that the brakes are spring-loaded to the “ON” position and require power to release them. In the event there is a loss of electrical power, the brake automatically applies to prevent the load from falling (fail safe).
Page 185 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 61 Typical Single Fall and Multi-fall Powered Chain Hoists Electric chain hoists are available for single or three phase power supplies. Hoists are also fitted with limit switches to prevent over-hoisting or over-lowering.
The hoist control pendant normally hangs 1 metre above the lowest position of the bottom hook. Electric hoists usually have swivelling top and bottom hooks for ease of attachment to suspension point and load. They can be hooked into a beam trolley for travelling along a runway beam or can be supplied with a `built-in' trolley to save headroom. Electric hoists are designed for vertical lifting. Electric hoists hooked or built into trolleys (or combined units) must be used for vertical lifts only.
4 3 .3
Pr e -u se
Check the following: 1.
Check hoist unique identification, WLL, date of inspection and next inspection due date are present and readable.
2. 3.
Check condition of the pendant control. Check the load chain for any obvious signs of damage, wear, excessive corrosion, cracks or distortion, signs of elongation.
4.
Ensure the load chain is adequately lubricated.
5.
Check load hook for distortion and ensure that the safety latch is operational.
6.
Check that the unit operates smoothly in response to controls and there is no abnormal noise from the winch during operation.
7.
Check limit switches function correctly.
8.
Check all electrical terminations
Page 186 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
9.
Check load chain sprockets for wear, damage and debris.
10.
Examine the general structure of the block for damage and that bolts and retaining screws are tight and not corroded.
4 3 .4
Sa f e U se
Observe the following 1.
Do not use the chain block load chain for slinging purposes, or make any modification to the way in which the chain block was designed to be used.
2.
Ensure chain block load chain is of adequate length for the proposed lifting operation and the load hook has adequate range of lift.
3. 4.
A chain block must be used for vertical lifts only. Do not attempt to operate the chain block beyond the maximum specified range. It is possible to impose excessive load on the chain anchor when the bottom hook is at its lowest position.
5.
When using a hook suspended chain block, ensure that the chain block hook can move freely and unhindered in the eye of the attachment point.
6.
After attachment, ensure that the load chain hang freely and where a bottom hook block is reeved with two falls ensure that the block has not 'turned-over' and the chain is not twisted.
7.
Do not allow dirt or grease to accumulate in the profiles of the load chain pocket wheels.
8.
If the load chain 'jumps' or does not operate smoothly it may not be sitting properly in the pocket wheel. This type of fault is more common on chain blocks with two or more falls where a load hook may have become ’turned over’, twisting the chain. If this is the case the block can be ‘flipped back’ to eliminate a twist in the falls. If after flipping back, the load chain still ‘jumps’ the chain may have been stretched, or there is damage to the pocket wheel, in either case the block must not be used.
9.
Ensure that shock loads are not imposed on the chain block.
Page 187 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
44.0 Lifting and Pulling (Tirfor) Machines Lifting and pulling machines are usually of the friction grip on cable type. A type commonly used is manufactured by Tirfor. This type of machine develops a pulling force on the load rope by a combination of alternate gripping and pulling (one grips while the other pulls) by two sets of jaws. The jaw mechanisms are operated by an external hand lever. Most other lifting and pulling machines that use a wire rope have a similar principle of operation. Tirfor rope hoists are available in several ranges the only range suitable in SMEP is the TU range. An example of a typical Tirfor lifting and pulling machines is shown at Fig 62.
Fig 62 Typical Tirfor Lifting and Pulling Machine
4 4 .1
T ir f or U se - Sa f e ty C onsid era ti on s
Tirfors’ will operate correctly only when used in conjunction with special load rope called 'Maxiflex'. This rope is manufactured in non-standard sizes designed to suit the gripping jaws of the Tirfor machine. It is therefore important to use the correct design and size of rope for the machine. A Tirfor will not operate safely or efficiently if wire rope other than the correct size Maxiflex wire rope is used in the machine. Tirfors are usually dual rated, with a WLL rating for lifting and a separate (usually higher) capacity rating for pulling. When selecting a machine, if both figures are present on the machine, in the interests of safety, selection must be based on the (lower) WLL rating. Shear pins fitted at the Tirfor hand lever mechanism ensure that excessive leverage cannot be applied to the machine mechanisms. Spare shear pins are usually kept in the hollow shaft of the operating lever stub.
WARNING: ONLY THOSE SHEAR PINS SUPPLIED BY THE MACHINE MANUFACTURER MUST BE USED. ONLY THE HAND LEVER SUPPLIED WITH THE MACHINE MUST BE USED. ONLY THE CORRECT SIZE ‘MAXIFLEX’ WIRE ROPE AS SUPPLIED BY THE MACHINE MANUFACTURER MUST BE USED. THE USE OF EQUIPMENT OTHER THAN THAT SUPPLIED BY THE MANUFACTURER WILL INVALIDATE CERTIFICATION AND MAY CAUSE THE MACHINE TO FAIL IN OPERATION.
4 4 .2
Pr e -u se
The following checks must be carried out before use:
Page 188 of 247
1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check Tirfor unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Generally check the machine and inspect for corrosion, deterioration and any other form of damage.
3.
Tirfors must only be operated with the correct size 'Maxiflex' wire rope. A Tirfor will not operate safely or efficiently if any other form of wire rope is used.
4.
Check that the shear pins are in position in the operating lever/spindle and that spare shear pins are present in the hollow shaft of the operating lever stub. Only shear pins supplied by the manufacturer shall be used in the operating lever of the Tirfor (Fig 63). The shear pin is intended to fail and protect the Tirfor mechanisms from overload in the event of excessive force being applied to the operating lever.
Fig 63 Tirfor Shear Pins
Page 189 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
5.
Check condition of Tirfor anchor point.
6.
Check for wear in the jaws as follows: a.
With no rope fitted (and lever in 'released' position) mark on the machine case the position of the rope release lever.
b.
Insert the correct rope into the machine and move the rope release lever to the 'jaws closed' position and make a second mark at the position of the rope release lever.
c.
The distance between the two marks must not be less than the manufactures stated limits.
d.
If the distance between the two marks is less than that stated by the manufacturer, wear on the rope jaws is indicated and the machine must not be used.
NOTE: REDUCTION IN ROPE DIAMETER MAY ALSO INFLUENCE THE ABOVE MEASUREMENTS. 7.
Thoroughly check the 'Maxiflex' wire rope as follows: a.
Ensure that the rope has no kinks. A kinked load rope will cause the machine to malfunction.
b.
Wipe the rope clean before fitting it to the machine and at the same time examine the rope for wear and damage. A damaged rope must not be used.
8.
Ensure that the machine is well lubricated. To lubricate both jaws of the machine place the reversing lever in a central position and using oil can 'squirt' medium gear oil into the mechanism, through the slot in the top of the casing, in front of and behind the reversing lever.
4 4 .3
I nse rti ng t he Ma xi fle x L oad R ope in t o t he Tir f or Mac hi ne
After inspection insert the 'Maxiflex' load rope into the 'Tirfor' as follows: 1.
Operate "Rope Release" mechanism to open jaws in machine.
2.
Insert the fused and tapered end of the load rope into the guide hole at the opposite end to the anchor and push the rope through the machine until it emerges from the guide hole at the anchor end.
3.
Pull the load rope through the machine until a working length is obtained.
4.
Operate "Rope Release" lever to close machine jaws onto rope.
4 4 .4
Sa f e U se
Observe the following: 1.
Do not allow the load rope to become kinked especially when uncoiling for use and when recoiling after use; even a slight kink can cause machine malfunction.
2.
Use only the hand lever provided for the machine.
Page 190 of 247
3.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ensure that the machine is anchored to a certified attachment point of adequate
capacity. 4.
The 'Maxiflex' wire rope must not be used as a sling, it will be damaged and rendered unfit for use in the Tirfor.
5.
Do not allow the load rope to rotate. This will unlay the strands and render the rope unfit for further use.
CAUTION:
4 4 .5
IF THE TIRFOR MACHINE FAILS MECHANICALLY DURING A LIFTING OPERATION, OR AN OPERATION WHERE THE LOAD IS BEING MOVED ALONG AN INCLINE, THE LOAD ROPE (AND HENCE THE LOAD) MAY NOT BE HELD.
A f ter Use
Proceed as follows: 1.
If a machine has become contaminated during use it can be dipped in paraffin, or alternative, suitable cleaning fluid, and shaken to dislodge foreign matter. Dry off and re-lubricate by applying medium gear oil through the top slot as previously described.
2.
For longer life and better performance, the wire rope must be lubricated with acid-free grease when it appears ‘dry’.
3.
Return the machine and rope (together) to the rigging store and complete the ‘returns’ procedure.
Page 191 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
45.0 Snatch Blocks Snatch blocks are used when it is necessary to change the direction of the pull on a line. A snatch block can be a single or multi-sheave block that has an opening side plate to allow a rope to be placed over the sheave pulley, thus eliminating the need for the rope to be threaded through the block. This is particularly useful where end fittings would hinder / prevent a rope from being threaded through a block. Where an anchored snatch block is used to change the direction of a line pull, the resultant stress on the anchor point depends on the angle between the 'load' line and the 'pull' (see Fig 64). This shall be borne in mind when selecting a snatch block and a snatch block anchor point.
4 5 .1
W ir e r ope P u lley Bl ock s
Pulley blocks or sheave blocks are available in the form of single sheave or multi-sheave with a choice of head fittings, the most popular being swivel shackle or swivel oval eye (Fig 64). The main function of a single sheave block is to change the direction of the hoisting or pulling rope. Multi-sheave blocks, when rigged in the normally used ‘advantage’ mode, reduce the pull required on the lead rope to lift a load. The pull required on the lead rope reduces as the number of falls (sheaves) increases.
Fig 64 Single and Multi-fall Sheave Blocks The two main types of block available are the multi-sheave block and single sheave block. Pulley blocks or sheave blocks are available in various capacities, and with or without beckets
NOTE: THIS SECTION DOES NOT APPLY TO DRILLING DERRICK BLOCK SHEAVES.
4 5 .2
Pr e -u se
Check as follows: 1.
Check snatch block unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Check that all moving parts operate freely.
3.
Check generally for wear, damage, distortion and any other damage (Fig 65). Do not use the block if any defects are found.
Page 192 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 65 Snatch Block Inspection
4 5 .3
Sa f e U se
Observe the following: 1.
Ensure that the sheave centre pin remains well lubricated, but do not over-lubricate.
2.
Ensure that rope(s) do not become twisted when reeving.
3.
Confirm that the structure to which the snatch block will be anchored is of adequate strength.
4.
Check that the clearance between sheave(s) and check plates, the clearance shall be small enough that there is no danger or the rope slipping between the sheave and side plates of the block.
5.
Where an anchored snatch block is used to change the direction of a line pull, the resultant stress on the anchor depends on the angle between the 'load' line and the 'pull' (Fig 66). This must be considered when determining the strength of the snatch block anchor point.
Page 193 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 66 Load On Snatch Block Anchor
4 5 .4
A f ter Use
Proceed as follows: 1.
Clean the snatch block, and check for damage and deterioration, in same manner as for pre-use inspection.
2.
Lubricate block centre pin and swivel(s).
3.
Return snatch block to rigging store and complete ‘returns’ procedure.
Page 194 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
46.0 Winches Winches are designed to be operated only when they are anchored to a firm foundation, e.g. floor or wall mounting. A typical manually operated winch and a pneumatically powered winch are shown on Fig 67. The majority of utility winches used on (spark free) offshore platforms are pneumatically powered. Most Winches (manual and powered) have two speeds of operation. Loads must never be lifted in high gear; high gear must be used only for rapid movement when unloading/lowering with no load, or light load on the hook.
M AN U AL L Y O P E R A T E D
PNEUM ATIC
Fig 67 Manually Operated and Powered Winches Winch selection is usually determined by their ‘line pull’. However, the majority of manufacturers' line pull ratings are based on ‘half drum’ performance and this line pull decreases as the drum fills up (see Fig 68).
FULL DRUM
MAX. SPEED MIN. PULL
HALF DRUM
MED. SPEED MED. PULL
1st WRAP
MIN. SPEED MAX. PULL Fig 68 Drum Capacity and Line Pull Diagram
NOTE: HALF DRUM RATING ESTABLISHES AVERAGE PERFORMANCE ONLY. THIS MUST NOT BE CONFUSED WITH WIRE ROPE CAPACITY, WHICH IS APPROXIMATELY ONLY 36% OF FULL DRUM STORAGE AT THIS POINT.
Page 195 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
A further consideration when selecting a winch for a particular operation is its drum capacity i.e. how much wire rope is required for the particular operation as this can often lead to a higher capacity winch being required due to loss of line pull. All powered winches must have a fail-safe braking system, i.e. spring applied and (pneumatic) power released. The design must be such that when the main control lever is returned to the neutral position, or in the event of an air pressure supply failure, the winch brake will automatically apply.
4 6 .1
M an -ri di ng W i n che s
Winches that are used for ‘lifting persons’ must comply with LOLER, Regulation (5)(1) (a) to (d) or ASME B30.23. Equipment used for lifting people shall have a safety coefficient relating to its strength of at least twice that required for general lifting operations. All winches suitable for man-riding operations must have a permanently and clearly marked, prominently displayed, rating plate indicating "SUITABLE FOR MAN-RIDING" or "SUITABLE FOR LIFTING PERSONNEL". Any winch not so marked must NOT be used for lifting personnel. Only winches that have been designed specifically for man riding can be used on SMEP operations. The winch-operating lever shall automatically be returned to neutral when released and the automatic brake shall be applied. The automatic brake shall also apply on loss of power and/or the control system. A winch used for the lifting and lowering of personnel must incorporate a secondary braking system, which is independent of both the automatic brake and the primary power source. This brake shall be of a simple design and preferably manual in operation (Fig 69). The design of the winch controls shall prevent inadvertent operation.
Automatic Brake
Manual Brake
Fig 69 Dual Brake System on Winches Winches used for lifting personnel shall not be fitted with clutches or any other means of disengaging the drive system. The winch drum and other moving parts must be suitably guarded. The guards must not inhibit the operator to view the spooling of the rope onto/off the drum. A clearly visible emergency stop device shall be located adjacent to and within easy reach of the operator's control station.
Page 196 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
The main hoist cable and attachments shall have a minimum factor of safety of 8:1 relative to the hauling load. The winch must be of adequate capacity to raise and lower the load at a speed not in excess of 10m/min and shall incorporate a load limiting device, which prevents loading the system in excess of the rated capacity (WLL) plus 50% or other loading, which will prevent the passenger being crushed. The winch shall also include an automatic cut-out device, which will shut off the primary winch power supply when the unit reaches the upper limit of its travel. The rated capacity of the winch must be based on the line pull on the top layer, with an 8:1 factor of safety. Devices shall be incorporated in the winch system, which prevent the personnel carrier from over-riding, under-riding and over speeding. The winch must have adequate capacity to handle the following load line condition with one wrap of rope spooled on the drum: 1.
Nominal weight of the persons carried.
2.
The tare weight of the basket/carrier.
3.
The rope weight and the friction effects of the sheaves etc,
Weight of additional personnel and equipment as may be needed to perform emergency operations. The sum of these weights shall include the factors of safety. The winch shall be capable of raising/lowering the carrier in a controlled manner in the event of an emergency or loss of power to the drive and/or control system. Means shall be provided to prevent rope entanglement, undue wear and to ensure the rope remains captive at all times around the sheaves and at the winch drum. The brake holding capacity shall be less than that generated by the minimum breaking load of the rope and greater than that generated by the maximum line forces due to the carrier, passengers etc. The rope shall be spooled on to the winch drum in a disciplined manner; i.e. bunching of the rope is not permitted. The design of the system shall ensure that the weight of the rope on the winch side of the sheave system is never greater than the minimum weight on the carrying side of the sheaves system.
NOTE: THE DESIGN AND OPERATIONAL ASPECTS OF THE WINCH SYSTEM SHALL BE CONFIRMED BY A HAZARD AND FMEA CARRIED OUT BY THE WINCH SUPPLIER. THE ANALYSIS SHALL INCLUDE THE IDENTIFICATION OF SAFETY CRITICAL ELEMENTS ON WHICH REGULAR INSPECTION, MAINTENANCE AND FUNCTION TESTING IS REQUIRED TO BE CARRIED OUT BY THE OPERATOR.
4 6 .2
H and -Op era ted W in che s
4 6 .2 . 1
Pr e -u se
Check as follows:
Page 197 of 247
1.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check winch unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Check all securing bolts are secure. Make sure the winch rope is of.
3.
a.
The correct size for the winch
b.
The correct length.
c.
Correctly anchored, and does not overfill the drum.
Check the winch brake and ensure that: a.
The winch is in the correct gear.
b.
The driving pinion is fully engaged.
c.
The pinion drive-locking device is secure.
d.
The handles are fully engaged.
e.
Check the operation of the pawl, it must engage completely with the ratchet wheel.
4 6 .3
Sa f e U se
Observe the following: 1.
Never attempt to lift a load in excess of the winch WLL.
2.
When lowering a load, use slow speed gearing.
3.
Check operation of brake for slippage; keep water/oil and dirt away from brake linings.
4.
Some winches have two speeds of operation and loads must never be lifted in high gear. High gear must only be used for rapid movement when unloaded.
4 6 .3
El ectr ic or Air Driv e n Win ch e s
4 6 .3 . 1
Pr e -u se
Check the following: 1.
Check hoist unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Inspect winch rope for obvious signs of damage, kinking, wear, and corrosion.
3.
Check winch drum for correct spooling of wire rope, if practicable check rope anchor for condition and security.
4.
Check brake bands for wear or contamination.
5.
Check all brake linkages for operation and condition.
6.
Check condition of operating lever, it must return to Neutral when released
Page 198 of 247
7. 8.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Check all fluid levels - top-up if required. Check load hook(s) for distortion and ensure that the safety latch is operational. (If fitted).
9.
Check delivery air pressure, all hoses and connections for air leaks.
10.
Check that the unit operates smoothly in response to controls and there is no abnormal noise from the winch during operation.
11.
Check all electrical terminations or air supply connections as appropriate.
12.
Examine the general structure of the winch for damage and that bolts and retaining screws are tight and not corroded.
13.
Check condition of the exhaust.
4 6 .4
Sa f e U se
Observe the following: 1.
Ensure all controls are clearly marked.
2.
Do not stand in line with the wire rope cable when it is under load or being lowered or raised.
3.
Winch operators must be wearing safety goggles and safety gloves.
4.
When paying out wire rope, ensure that personnel are kept clear of the loose rope.
5.
Do not stand on the winch machinery.
6.
Do not hand wind a wire rope on to a drum.
7.
Do not work too close to the drum, the wire rope could ‘Jump’ and trap hands or clothing.
8. 9.
Do not operate a winch until all protective guards and covers are fitted. Do not cross the wire rope on the drum; it will crush or flatten the rope, rendering the rope unserviceable.
10.
Ensure a fleet angle of ¼º - 1¼º for grooved drums and 1º - 3º for plain drums is not exceeded.
Page 199 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
47.0 Hydraulic Jacks, Rams and Pumps Hydraulic lifting equipment is available in two basic arrangements: 1.
A combined unit consisting ram/plunger and cylinder assembly with an integral pump unit (see Fig 70(a))
2.
A set consisting of a separate ram and pump interconnected by a high pressure hose (see Fig 70(b))
The operational situation will determine selection of hydraulic jack type.
(a)
(b) Fig 70 Hydraulic Jack Units
The jack must be marked with its identification number and WLL and in the case of a toe-jack, the WLL, which may be lifted on the toe, must be marked on the jack in addition to WLL of the jack head.
For environments where there is a lack of space to insert a jack, some models of jack (with extended bases) can be fitted with a claw attachment. The use of a claw attachment (Fig 71) reduces the capacity of the jack by approximately 40% of its original capacity refer to manufacturers manual.
Fig 71 Claw Attachment Fitted to Hydraulic Jack
As an alternative to a jack with a claw there are low-headroom rams known as pancake rams or pad jacks. However the major drawback with this type of jack is its very limited stroke.
Some designs of jack have rams with locking collars, which can be adjusted to prevent ram creep when a load must be sustained at a particular height (see Fig 72).
Page 200 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 72 Hydraulic Ram with Locking Collar
As an additional safety measure, a lock off safety valve can be fitted to the ram to maintain pressure in the event of a hose failure.
Standard rams and jacks are not suitable for sub-sea work; specialised jacking equipment is required for sub sea work.
4 7 .1
Pr e -u se
Check the following: 1.
Check jack unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
In the case of a toe-jack, the WLL, which may be lifted on the toe, must be marked on the jack as well as the WLL of the head.
4 7 .2
R a t ch e t Ja ck s
1.
Check for wear on the jack pawls.
2.
Check for wear at the linkages and on the sliding surfaces.
3.
Check correct functioning of the whole mechanism.
4.
Ensure the rack is greased, except on the teeth side; keep the teeth clean.
4.
Ensure all bushes and bearings are clean and adequately lubricated.
4 7 .3
H ydra uli c Ja ck s
1.
Check for fluid leakage; do not use the jack if there is evidence of fluid leaks.
2.
Check hydraulic fluid level.
3.
Check for bends and/or cracks in the foot or body.
4.
If the jack is of the separate pump type, check condition of connecting hose and hose connectors.
Page 201 of 247
4 7 .4
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Sa f e U se
The following checks apply cover mechanical and hydraulic jack assemblies: 1.
Apply the load centrally and in line with the jack/ram and do not exceed rated
capacity. 2.
Fully support the base of the jack/ram.
3.
Stabilise the base of pump unit to prevent overturning when pumping.
4.
Ensure that a jack with a claw attachment has an extended base.
5
Screw down locking collar (where fitted) when the load is to be sustained.
6.
Open hydraulic release valve slowly when lowering load.
7.
Check pressure rating of hoses/gauges/fittings etc.
8.
Keep the ram/piston clean.
9.
Fully retract ram before disconnecting hydraulic hose(s).
10.
Do not go under a load supported solely by jacks. A load must not be left supported entirely by jacks.
11.
When a load is being jacked up, it must be followed closely by the insertion of suitable packing, so that in the event of the jack slipping or failing, the load will only have a short distance to fall onto the packing.
12.
Do not drop loads onto jacks/rams.
13.
When using jack claw attachments, it shall not exceed 40% of the jack capacity, or stated in the manufacturers operational manual.
4 7 .5 1.
A f ter Use When not in use keep ram under a small pressure so that the leather cup washers remain expanded.
2.
Check jack as for pre-use checks and return to rigging store and complete ‘returns’ procedure.
Page 202 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
48.0 Overheard Cranes Overhead cranes are available with two basic bridge designs i.e. single girder and double girder. With single girder construction, the hoist unit is suspended from a trolley mounted on the lower flange to provide “cross travel” (see Fig 73).
Attention is drawn to Shell’s global standard on lifting and hoisting EP2005-0264-G01 (section 5 page 16)
Fig 73 Overhead Crane - Single Girder Type
Fig 74 shows the double girder type of overhead crane where the crab unit travels on rails mounted on top of the girders or between them with the crab wheels running on the lower inside flanges.
Fig 74 Overhead Crane - Double Girder Type Double girder cranes have an advantage over single girder cranes in that they have reduced headroom and increased height of lift due to the decreased beam depths and the ability to raise the hook up between the beams. In both types of overhead crane, long travel is obtained by means of carriages fitted at each end of and at right angles to the cross girder(s).
4 8 .1
H oi sti ng and Tr ave lli ng U ni t s
The hoisting unit can either be:
Page 203 of 247
1. 2.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
A standard under-slung trolley hoist (fitted with either wire rope or chain) or, A crab unit mounted between or on top of the bridge girders (for wire rope only). The bridge being compatible with the width of the building or module.
The hoisting unit and travelling unit, may be electrically, pneumatically or hydraulically powered - or manually powered (through hand chains). A combination of powered and manual operation is also possible.
Most powered units have either single speed or dual speed options but all are fitted with over hoist limits as a safety feature. Additional safety features that are fitted to most units are cross travel and long travel brakes/limit switches, and in some applications, anti-collision limit switches if more than one crane operates on the same rails.
All offshore overhead cranes must be coated for use in a marine environment.
All electrically powered cranes must be rated appropriate to the zone in which they are fitted.
CAUTION MANUAL OR POWERED OVERHEAD TRAVELLING CRANES SHALL NOT BE USED FOR LIFTING PERSONNEL
4 8 .2 1.
Pr e U se Check overhead travelling crane unique identification, WLL, date of inspection and next inspection due date are present and readable.
2.
Ensure a competent Signal Person is nominated. Except in circumstances where fewer than three people are available for the lift, the Signal Person shall serve that role only and shall not simultaneously act as a rigger.
3.
Ensure a competent rigger is used to act as a load handler for lifting operations. Except in circumstances where fewer than three people are available for the lift, riggers shall serve that role only and shall not simultaneously act as the Designated Signal Person.
4.
In circumstances where fewer than three people (competent operator, signal person, and rigger) are available to conduct a lift, a JSA must be carried out.
5.
Discuss the circumstances of the lifts with all personnel involved with the lift, including but not limited to the operator, signal person, and riggers before any lift is made.
6.
Obtain all pertinent information (weights, hazardous material, etc.), prior to commencing lifting operations.
7.
Crane load limits must be adhered to at all times.
8.
The competent operator for overhead cranes must know the weight of the load and assure that it is within acceptable limits of the crane before lifting.
9.
The competent operator for overhead cranes, in conjunction with the rigger, is responsible for ensuring that all loads are properly rigged before lifting.
Page 204 of 247
10.
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Before starting the crane, the competent overhead crane operator must do the
following: a.
Conduct and document the pre-use inspection.
b.
Ensure all controls are in the "off" or "neutral" position.
c.
Ensure all personnel are in the clear of the load.
4 8 .3
Sa f e U se
While using the crane, the competent operator for overhead cranes shall do at least the following to assure clear communications are maintained: 1.
Only respond to signals from the Signal Person, (but must obey an emergency signal regardless of who gives it).
2. 3.
Ensure communication is established & maintained with the Signal Person. Ensure that signals from the signal person are always understandable either verbally or visually. The operator must not respond unless signals are clearly understood. Ensure that the signal person is in clear view, when appointed (unless during blind lifting operations).
4.
Ensure that the signal person can clearly see the load, crane, personnel and area of operation (unless during blind lifting operations).
5.
Ensure proper and correct use of standard hand signals. Develop special signals when the situation requires it and ensure that the designated signal person and overhead crane operator understand and agree with the special signals.
6.
Conduct load movement only on instruction from the Signal Person.
7.
The Operator for overhead cranes shall do at least the following to assure safe handling of loads: a. b.
Be at the crane controls at all times while a load is suspended Keep loads in sight at all times until the load and tag line (where applicable) have safely left the ground (unless during blind lifting operations).
c.
Ensure the load is attached to the hook by means of slings or other suitable devices. The latch must be closed to secure loose slings.
d.
Ensure the hoist rope is not wrapped around the load.
e.
Properly use slings in accordance with section 15.9, 15.10 and 15.11.
f.
Take care when travelling the crane to minimize the swinging pendulum action of the hook and suspended load.
g.
Ensure all personnel are clear of the lifting operation.
h.
Always maintain at least two wraps on the hoist drum in any operating condition.
Page 205 of 247
4 8 .3 . 1
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
D o No t :
1.
Travel the crane at excessive speed
2.
Travel the crane into end stops or other crane except at very low speed
3.
Use the crane for dragging loads unless properly rigged for a vertical pull that does not exceed the rated capacity
4.
Hoist, lower or travel the load while personnel are on the load.
5.
Hoist a load over personnel.
Additionally, tag lines may be used at the discretion of the operator and/or as determined by a JHA where appropriate. When used, tag lines they shall have a minimum extended length of 2 metres. Riggers must never stand under a load to grasp tag lines.
Page 206 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
49.0 Vehicle Loading Cranes (e.g. Hiab Crane) A vehicle-loading crane is a crane, which is used to load and unload own cargo aboard the vehicles. This crane can also be used for general lifting operations if certified, refer to the crane’s capacity charts. Vehicle-loading cranes can be used for the following: 1.
The crane is assembled on a device that is designed and constructed for the transportation of loads.
2.
The crane is assembled on a device that has not been fitted out for the transportation of loads.
The crane is also used for other lifting operations other than loading and unloading of it’s own vehicle.
4 9 .1 1.
Pr e U se Check vehicle loading crane unique identification, SWL, date of inspection and next inspection due date are present and readable.
2.
Ensure a competent banksman and rigger are nominated. It is acceptable to have the Banksman act simultaneously as a rigger.
3.
Check for fluid leakage; do not use the crane if there is evidence of fluid leaks. Check hydraulic fluid level.
4 9 .2 1.
Sa f e U se The vehicle-loading crane must be used with the outriggers in the maximum extended position and conform to the capacity lift plan and manufacturer’s instructions.
2.
Outriggers must be installed at an equal maximum distance. When insufficient surface support, blocking are to be used. Blocking must be made of sound and strong material.
3.
The vehicle-loading crane shall only be used within the radii indicated and in conformance with the capacity chart.
4.
Vehicle loading cranes with a working load of more than 1000kg shall be provide with a Load Moment safety device.
5.
Vehicle loading cranes with a working load of less than 1000kg may be provide with a hydraulic overpressure safety device.
6.
An audible signal shall be installed with cranes of a reach of 12M and on cranes with a remote control.
NOTE: IT IS A REQUIREMENT THAT ALL VEHICLE LOADING CRANES WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE.
Page 207 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
50.0 Flexible Intermediate Bulk Containers (FIBC) 50.1
Li fti ng of fil led F IBCs
Flexible intermediate bulk containers are used for the bulk transport of non-hazardous powder and granular material. They are designed to be lifted vertically from above.
5 0 .2
Pr e -U se
Before lifting, FIBCs must be thoroughly examined for damage to stitching/gluing/welding and for surface abrasion, cuts, tears or any other damage to the bag. Particular attention must be paid to the lifting loops. The examination shall look for signs of the following: 1.
Abrasion; the effects of abrasion are variable, but some loss in strength is to be expected. In extreme cases, the fabric becomes so worn that the outer yarns of the weave are severed. On lifting loops, localized areas of abrasion may be present caused by handling equipment with sharp edges, and these areas may result in a serious loss in strength.
2.
Cuts, contusions cuts, particularly in the lifting loops or devices, may result in a serious loss of strength.
3.
Ultra violet degradation and/or chemical attack. These may be indicated by the softening of the material (sometimes with discoloration), so that the outer surface may be rubbed off or plucked off, and in extreme cases, the outer surface may become powdered.
Ensure the lifting loops are positioned according to the manufacturer's instructions. Inspect the hooks, bars or fork lift arms employed for lifting to ensure that they have rounded edges with a radius greater than the diameter or thickness of the suspension of the FIBC and/or be protected by wrapping. The rounded edges shall have a minimum radius of 5 mm.
5 0 .3
R epa ir of FI BCs
Repairs must never be carried out on damaged FIBC's. Damaged FIBC's must be effectively destroyed.
5 0 .4
H ow t o use FI BCs
The approved number of trips for a FIBC must not be exceeded i.e. single trip bags must only be used once. FIBCs for hazardous materials must meet the special requirements set out in BS 6939 Part 1, and FIBCs which are not intended for hazardous materials must not be used for that purpose.
Some chemicals and minerals are of a specific gravity. As a result, the SWL may be reached when the FIBC is only partially filled. Cargo weight must be closely monitored and allowances made if the contents become wet. During the use and transportation of FIBCs, personnel must:
Page 208 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
1.
Ensure they are filled in accordance with manufacturer's recommendations.
2.
Avoid using sharp hooks or forklift truck forks, which may damage the lifting loops.
3.
Avoid dragging them along the ground or deck.
4.
Ensure that they do not project over the side of a vehicle or trolley.
5.
Not stand under a suspended FIBC.
When FIBCs are used outdoors: 1. 2.
Particular attention must be paid to the top closure and its tying off arrangement. They must be protected from rain accumulation, excessively high temperatures and ultraviolet light.
3.
They must not be left standing in water for extended periods of time. DO
DON'T
Do select the right FIBC for the job in consultation with the manufacturer or supplier
Don't choose FIBCs without consulting the manufacturer or supplier
Do read the instruction label on the FIBC
Don't exceed the SWL in any circumstances
Do inspect re-usable FIBCs before refilling
Don't fill the FIBCs unevenly
Do check that the discharge spout is closed off before filling
Don't stop or start suddenly during transportation
Do ensure that the filled FIBC is stable
Don't subject FIBCs to snatch lift and/or jerk stops
Do close the top inlet correctly
Don't drag FIBCs
Do use lifting gear of sufficient capacity to take FIBCs the suspended load
Don't allow personnel under suspended FIBC’s
Do adjust the distance between fork lift arms to the correct width for the FIBC being handled
Don't allow FIBCs to project over the side of a vehicle or pallet
Do tilt the mast of the fork lift truck rearwards to an appropriate angle
Don't tilt the mast of the forklift forward
Do ensure that crane hooks, bars or forklift arms used for lifting are of adequate size and are rounded to at least the thickness of the sling, belt or rope suspension, with a minimum radius of 5 mm.
Don't withdraw the fork lift tines prior to relieving all the load on the lifting devices
Do take appropriate measures in regard to dust control
Don't stack FIBCs unless sure of stability
Do consider the possibility of static electricity
Don't use FIBCs in new conditions without consulting the manufacturer or supplier
Do protect the FIBCs from rain and/or prolonged sunlight
Don't reuse single-trip FIBCs
Do ensure the FIBCs are adequately secured in transportation
Don't repair heavy duty reusable FIBCs unless the new requirements can be met
5 0 .5
Li f ti ng FI B Cs
When lifting FIBCs with a forklift truck, be sure that the forklift tines are spaced correctly. All lifting loops, sleeves, or other lifting devices are vertical, so that no lateral forces will be
Page 209 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
created in the FIBC. Be sure that the lifting loops are not twisted. Forklift tines must have rounded edges and/or protective covers FIBC’s.
5 0 .6
Li f ti ng wi t h Cr a ne s
The hooks, spreader bars or other devices used for lifting, must have rounded edges and/or protective covers.
Safety hooks with an integrated latch to prevent the hook from accidentally slipping off the loops. Hooks must have a sufficiently large radius to prevent squeezing the loop.
When the FIBC is suspended, the loops must be vertical, without any twists or knots.
Fig 75 Lifting of FIBC’s offshore is not allowed. FIBC’s being transported offshore must be transported using a fully certified lifting frame. The lifting frame must be approved by SMEP’s Lifting Technical Authority prior to its utilisation.
5 0 .7
C a r r yi n g W i t h F or k Lif t Tr u ck s
The forklift truck must be suitable for the load to be carried. When travelling with a FIBC hanging from the forklift tines, there is a danger of the truck becoming unstable. The FIBC must be held close to the mast and as low as possible with the mast tilted slightly backwards. Make sure that the wheels of the truck will not damage the FIBC body. The load must not restrict the view of the driver.
Fig 76 FIBCs must not be dragged. The truck must be brought to a stop before the FIBC is raised or lowered smoothly.
Page 210 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fig 77
Page 211 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
51.0 Containers The containers referred to here meet BS EN 12079 specifications for freight containers of the totally enclosed general purpose type for transportation by road or sea.
Before loading a freight container with cargo, an internal and external inspection must be carried out to ensure that: 1.
The container shows the tare weight, payload (SWL), maximum gross weight, ID number and date of inspection and next due date.
2.
The attached lifting set is within the specified inspection period and colour coded to this effect.
3.
The attached lifting set is of the correct length to achieve the maximum lifting angle of 45° to the vertical
4.
Ensure that the attached lifting set is of adequate length to allow the rigger/slinger to place the master link onto the crane pennant hook without the need to climb.
5.
Shackles must be of the 4-part bow safety-anchor type, with retaining nut and split pin. Screw pin shackles must not be used. a.
There is no obvious damage such as distortion of floor/sides/roof, bent lifting eyes or cracked welds.
5 1 .1
W ir e r ope s li ng s
Most containers are fitted with multi-leg wire rope slings, which are rated for use up to an angle of 45° (angle measured from the vertical of the diagonally opposite legs) and have an in-built factor of safety (FOS) of 5: 1. This is based on the maximum gross weight of the container. It is a requirement that any sling set fitted to a container used for offshore lifting an additional safety factor is required to be included. Refer to table below:
Sling Capacity
Safety Factor
Less than 6 tonnes
10
6 to 10
8.5
10 to 15
7.25
15 to 20
6.5
20 to 25
6.25
All slings legs, which are connected directly to master links or shackles, must have thimbles or hard eyes to reduce the bend radius on the wire rope and therefore increase their serviceable life.
Container sling sets may be fitted with a top lifting leg or fifth leg and master link (fig 78), which is designed to hang over the side of the container to facilitate hooking up. This eliminates the need for personnel having to climb on top of containers to attach or detach the
Page 212 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
crane hook, which, could be particularly hazardous on marine vessels. This fifth leg is not a design requirement but a more practical method.
Fig 78 Typical rigging arrangement for containers
5 1 .2
I SO C o nt ai ner s
Even onshore or in still water port situations, ISO containers cannot be lifted from the ISO corner fittings by shackles and slings or hooks as they are designed only for vertical lifting. This applies even when empty. Lifting with spreader frames as used in port situations is not allowed in offshore lifting operations. Refer to IMO MSC circular 860. ISO containers used offshore must have pad eyes that are purpose built for offshore lifting. It is appreciated that from time to time there may be a requirement to send ISO containers or ISO tanks offshore, which do not comply with Shell Malaysia E & P’s requirements. In this situation a fully certified proprietary ISO container-lifting frame must be used. The proprietary ISO container-lifting frame must be approved by SMEP’s Lifting Technical Authority prior to its utilisation.
Page 213 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
52.0 Pennants/Stingers A pennant must be used for all lifts to and from supply vessels, work boats etc. All pennants must be fitted with a scissor action self-latching type hook with trigger release handle; this ensures that the rigger’s hands are kept away from the hook’s pinch points. It also has the facility to attach the tag line to the hole in the bottom of the trigger assembly.
5 2 .1
P en na nt A ss e mb l y
The pennant must be manufactured in accordance with BS EN 13414-1, from wire rope, which meets the requirements of BS EN 12385-4, or an equivalent International Standard. Pennants are required to meet the requirements above and in addition the following requirements: 1.
The construction shall be with hard eyes terminations, a hook on one end and a master link at the other end.
2.
The attached hook shall be of a swivel scissor action self-latching type hook with trigger release handle design. (See fig 16A).
3.
The hook shall have a working load limit at least equal to the one leg sling working load limit listed in BS EN 13414-1 table 4.
4.
The master link shall be of a suitable size to fit the crane hook, but must have a working load limit at least equal to the one leg sling working load limit listed in BS EN 13414-1 table 4.
5.
A hi-visibility cover for the wire rope portion is recommended.
6.
Pennants shall have a minimum capacity to lift 125% of the planed load, and the wire rope shall not have a diameter less that 22mm.
7.
A pennant must be used for all lifts to and from supply vessels, work boats etc. In exceptional circumstances were due to jib length/height restriction it is not possible to use a pennant, a tag line must be attached just above the crane hook. The crane operator and vessel's crew must exercise utmost caution.
Fig 79 Typical Pennant assembly
Page 214 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 1
Crane Banksman Hand Signals
Prior to any lifting operation being made, a banksman is to be appointed and identified to the crane operator. This applies without exception in all cases. The banksman is the only person permitted to pass instructions to the crane operator, and the crane operator is not permitted to follow instructions from persons other than the banksman. The banksman must direct lifting operations and signal to the crane operator using standard hand signals as illustrated in Fig 1.
STOP - Extend one arm and hold palm of hand vertical. Note: EMERGENCY STOP is indicated by holding both arms up
STOP (B) - Arm extended, palm down, move hand right and left. Usually for different level operations.
STOP AND LOCK (HOLD EVERYTHING) Clasp hands in front of body.
MOVE SLOWLY - Place one arm motionless across chest in conjunction with or before giving any other directional signal. (“Hoist slowly” shown as example.)
HOIST - With forearm vertical, forefinger pointing up, move hand in horizontal circles.
LOWER - With arm extended downward, forefinger pointing down, move arm in
Page 215 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
horizontal circles.
USE MAIN HOIST - Tap fist on head, then use regular signals.
USE FLYLINE (AUXILIARY HOIST) - Tap elbow with one hand, then use regular signals.
RAISE BOOM (LUFF UP) - Arm extended, fingers closed, thumb pointing upward.
LOWER BOOM (LUFF DOWN) - Arm extended, fingers closed, thumb pointing downward.
SLEW - Arm extended, point with finger in direction of swing of boom. OVERHEAD GANTRY CRANE - Arm extended, point with finger in the long-travel or cross-travel direction.
EXTEND HYDRAULIC BOOM OR TROLLEY OUT (TOWER CRANE) - Both fists in front of body with thumbs pointing outward.
Page 216 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
RAISE THE BOOM AND LOWER THE LOAD (A) - One arm extended, thumb pointing upward flex fingers in and out as long as load movement is desired.
LOWER THE BOOM AND RAISE THE LOAD (A) - One arm extended, thumb pointing downward flex fingers in and out as long as load movement is desired.
RETRACT HYDRAULIC BOOM OR TROLLEY IN (TOWER CRANE) - Both fists in front of body with thumbs pointing toward each other.
RAISE THE BOOM AND LOWER THE LOAD (B) - One arm extended, fingers closed, and thumb pointing upward. Other arm extended downward with forefinger pointing down, move arm in horizontal circles.
LOWER THE BOOM AND RAISE THE LOAD (B) - One arm extended, fingers closed, and thumb pointing downward. Other arm vertical with forefinger pointing up, move arm in horizontal circles.
TRAVEL - Arms bent at the elbows, fists clenched, rotate both forearms around each other, then point in the direction of travel.
Page 217 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
TRAVEL (ONE TRACK - CRAWLER CRANES ONLY) - Lock the track on the side indicated by the closed fist. Travel opposite track in the direction indicated by circular motion of other fist rotated vertically in front of body.
FINISHED WITH CRANE - Place arms above head and cross hands.
A crane must not be operated unless: The banksman has a clear view of the load, lifting assembly and crane operator to give signals. The banksman has checked that riggers and all other personnel are clear of the vicinity of the load. The crane operator has a clear view of the banksman to receive signals. Banksmen, riggers and other personnel involved in crane operations must wear safety helmets and other relevant personal protective equipment. The crane operator is exempt from this requirement while he is in the crane cab, operating the crane. Crane activities must cease in the event of any emergency or potentially dangerous situation and the crane operator must immediately obey all emergency stop signals.
Page 218 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 2
Flow Chart Lifting and Hoisting Operations LIFT REQUIRED
NON-ROUTINE
Simple Lift
Risk Assessment (New or modified)
Complicated Lift
Lift Plan (New) Approved by TA
APPOINT PIC & DEFINE LIFT
ROUTINE
No
Complex Lift
Lift Plan (New) Approved by TA
Review previous risk assessment and lift plan
Risk Assessment (Generic) Approved by PIC
Proceed and verify lift by toolbox meeting, PTW Page 219 of 247
NEW LIFT
Yes
Changes in situation
Risk Assessment (New or modified) Approved by PIC
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 3
Mobile Crane Lift Planning Sheet
Description of lift: Location Generic Lift plan No.
3. RIGGING REQUIRED Shackle set 1 Type Shackle set 2 Type Sling set 1 Type Sling set 2 Type 4. RIGGING WEIGHT Description Headache Ball & hook Load line Fly Jib Fly Headache Ball & hook Rigging i.e. sling shackles Spreader bar Other rigging attached Total
Permit to work Number Risk assessment No. 1. CRANE DATA Crane Reg. No. Inspection Date Next due date Crane capacity Kgs Max working radius Mtrs Max boom length Mtrs Max lifting height Mtrs Parts of line The crane capacity charts must be consulted for operation restrictions i.e. over the rear only, outriggers fully extended 2. LOAD DATA Object to be lifted Weight of Load Container/Vessel - Empty YES NO Awkward Shape YES NO CofG Known, could it change YES NO Certified lifting points YES NO Special Rigging required YES NO Special rigging techniques YES NO required Other Capacity Capacity Capacity Capacity Weight
kgs kgs kgs kgs Units kgs kgs kgs kgs kgs kgs kgs kgs
Quantity Weight Quantity Weight Quantity Weight Quantity Weight 5. RIGGING CALCULATION Description Weight Object weight (2) Contingency % Rigging weight (4) Total weight Maximum Radius Lift height Boom length Capacity chart rating at radius & boom length % of chart capacity % safety margin
kgs kgs kgs kgs Units kgs kgs kgs kgs M M M kgs
6. CATEGORY OF LIFT Tick which ever is applicable Routine Lift plans shall be written by rigging foreman or crane operator and approved by person in charge (PIC) of the lifting operation. Simple Lift plans shall be written by a rigging supervisor and approved by person in charge (PIC) of the lifting operation. Complicated Complicated lift plans shall be written by an approved lift planner and approved by T.A. Complex Complex lift plans shall be written by an professional engineer and approved by T.A. 7. HAZARDS CRANE SET-UP/OPERATING AREA 7.1 Underground Hazards 7.2 Ground level Hazards 7.3 Above ground Hazards
Page 221 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Utilities – Gas, Water etc Storm Drain Sewer Recent excavations Other - describe
Members of the public Workers Vehicles/machinery Buildings Ground conditions Other - describe
Electrical cables Telephone cables Lampposts Other cranes Trees Conflicting tasks in area Other - describe
Access road: Concrete/Bitumen/Gravel/soft/Other Crane Set-Up Area: Concrete/Bitumen/Gravel/Soft/Slope /Other The lifting activity requires the following to be considered, note this list is not exhaustive Cultural, communication and language difficulties Environmental conditions including weather and permissible limits Weight, size, shape and centre of gravity of load Illumination in the pick-up and lay-down areas Availability of approved lifting points on load Proximity of hazards, obstructions in the path of load Method of slinging/attaching/detaching the load Contingency plan in case the task changes Overturning/load integrity/need for tag lines Access and emergency escape routes Initial and final load positions and how it will get there Experience, competence and training of personnel Lifting over live equipment Number of personnel required for task Number and duration of lift(s) Pre-Use Inspection of equipment by Operator Tool Box Talk, including Safety and Stopping the job 8. PERSONNEL Personnel Name Signature Date Crane Operator Banksman Rigger 9. APPROVALS Required lift Approvals Name Signature Date Lift plan prepared by Lift plan reviewed by Lift Plan approved by Lifting details (step by step)
Page 222 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 4
Appliance Lift Planning Sheet
Description of lift: Location Generic Lift plan No.
Permit to work Number Risk assessment No. 1. APPLIANCE DATA Appliance. No. Inspection Date Next due date Appliance capacity Working Height 2. LOAD DATA Object to be lifted Weight of Load Awkward Shape CofG Known, could it change Certified lifting points Special Rigging required Special rigging techniques required Other 3. RIGGING WEIGHT Slings Shackles Other rigging
Kgs Mtrs
YES YES YES YES YES
NO NO NO NO NO
4. RIGGING CALCULATION Description Weight Object weight (2) Contingency % Rigging weight (3) Total weight Lift height % of capacity % safety margin 5. RIGGING REQUIRED Shackle set 1 Type Capacity kgs Quantity Weight Shackle set 2 Type Capacity kgs Quantity Weight Sling set 1 Type Capacity kgs Quantity Weight Sling set 2 Type Capacity kgs Quantity Weight 6. PRE USE CHECK LIST Item Pre Inspection 1 Examine top and bottom hooks and check for stretch and/or distortion. 2 Check function of safety catches. 3 Ensure hooks swivel freely in yokes and are secure in their mountings 4 Where accessible, examine load pin for wear and/or distortion. 5 Examine load chain sheaves, check for wear and/or distortion and ensure satisfactory seating of load chain. 6 Examine body casing and check for cracks, distortion, missing bolts/screws or any defect, which may affect safe operation. 7 Examine (as far as possible) internal frame side plates. 8 Ensure chain guide rollers and chain stripper are in position and functioning. 9 Examine live end and dead end load chain anchor pins and check for distortion/wear.
Page 223 of 247
Units kgs kgs kgs kgs M
kgs kgs kgs kgs Yes
No
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
10
Suspend hoist and spin hand chain wheel (in hoist mode) to check ratchet pawl function-listen for healthy clicking sound. 11 Examine hand chain wheel and chain and ensure it seats correctly in the pockets. 12 Examine complete length of load chain and check for stretch, deformed/bent links, nicks, wear and excessive corrosion. 7. CATEGORY OF LIFT Tick which ever is applicable Routine Lift plans shall be written by a rigging supervisor and approved by person in charge (PIC) of the lifting operation. Non-Routine Lift plans shall be written by an approved lift planner and approved by T.A 8. HAZARDS APPLIANCE RIG-UP AREA 8.1 Ground level Hazards 8.2 Above ground Hazards Workers Cables Obstructions Live lines Buildings Conflicting tasks in area Other - describe Other - describe
Appliance Rig-Up Padeye, Trolley, Beam clamp The lifting activity requires the following to be considered, note this list is not exhaustive Cultural, communication and language difficulties Environmental conditions including weather and permissible limits Weight, size, shape and centre of gravity of load Illumination in the pick-up and lay-down areas Availability of approved lifting points on load Proximity of hazards, obstructions in the path of load Method of slinging/attaching/detaching the load Contingency plan in case the task changes load integrity/need for tag lines Access and emergency escape routes Initial and final load positions and how it will get there Experience, competence and training of personnel Lifting over live equipment Number of personnel required for task Number and duration of lift(s) Pre-Use Inspection of equipment by Operator Tool Box Talk, including Safety and Stopping the job 9. PERSONNEL Personnel Name Signature Date Crane Operator Banksman Rigger 10. APPROVALS Required lift Approvals Name Signature Date Lift plan prepared by Lift plan reviewed by Lift Plan approved by Lifting details (step by step)
Page 224 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 5 Date/Time
Carrier Transfer Checklist
Reason for Transfer
No of people to transfer
Transfer from:
No
Description
Minimum Requirement
1a
Crane suitability Crane & Lifting Equipment Take-off and landing area
The crane is registered and approved for personnel basket transfer with SMEP’s Lifting Technical Authority? Pre-use inspections have been undertaken?
1b 2
3a 3b 3c 3d 4a 4b 5a 5b 6 7 8a 8b
Weather criteria Weather criteria Vessel Movement Vessel Movement Communicati on Visibility Transfer carrier Transfer carrier Crane Operator Assisting Personnel Personnel transferring
9
Personnel transferring Personnel transferring Personnel transferring Personnel transferring Briefing
10
Toolbox talk
11
Toolbox talk
12
Recovery Craft
8c 8d 8e
Transfer to:
Crane Driver
SMEP Site Rep
Vessel Master
Are take-off and landing area level, free of obstruction, have a non-slip surface and have sufficient clear space (6m x 6m minimum) for landing the carrier in the prevailing weather condition? Significant wave height not more than 2 m. Mean wind velocity of 10 m/s knots or 6 m/s in weather side. Less than 3 degrees roll. Vessel can hold station for 3 minutes in the required transfer position - verified by Master of vessel Full radio contact between Installation Supervisor, Vessel Master, Crane Operator and Banksmen? Does crane operator have full view of the take-off and landing area including lifting trajectory? Is transfer carrier certified for man riding and in good condition? Two taglines attached to the carrier, and without knots Is crane operator certified by a SMEP approved training provider and assessed for competency and has the experience in carrying out personnel carrier transfers? Banksman with banksman’s jacket and two assistants at the take-off and landing area? All personnel transferring are wearing Coverall, Safety Footwear, Safety Helmet with chinstrap Safety Glasses and an approved buoyancy device? Maximum 3 persons per transfer? Checked for loose items? All passengers agreed to the transfer? An experienced person accompanies inexperienced people. All personnel transferring have received a full briefing and signed form in appendix 6? Toolbox talk held with all personnel involved in the transfer i.e. Crane Operator, Banksman etc? Toolbox talk held by Vessel Master, with Officer and crew? Fast rescue boat deployed?
All the checks found to be satisfactory: _________________ Work Site Supervisor Name:
________________ SMEP Site Representative Name:
Page 225 of 247
_________________ Vessel Master Name:
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 6
Carrier Transfer Passenger Checklist
By signing this document, I confirm that the following statements are true: I have received a briefing about personnel transfer by carrier. I understand the procedures shown. I agree to transfer by this method. I understand that this transfer will take place on a voluntary basis only. I am physically fit to transfer, and do not suffer from vertigo (fear of heights). Date/Time
No
Reason for Transfer
Passenger Name
No of people to transfer
Company
Transfer from:
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Page 226 of 247
Transfer to:
Signature
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 7 Personnel Transfer Request SMEP PERSONNEL TRANSFER REQUEST TRANSFER NO. __________________ DATE________________
COMPANY _________________________
FROM (UNIT) ________________________
TO (UNIT) _________________________
NUMBER OF PERSONS (MAX 3) TIME TRANSFER REQUIRED _______________________ PERMIT TO WORK NUMBER _______________________ REQUESTED BY _________________________________ POSITION _______________________________________ JUSTIFICATION FOR TRANSFER
APPROVAL SMEP SITE REPRESENTITIVE NAME ___________________________________
SIGNED ____________________________
---------------------------------------------------------------------VESSEL MASTER NAME ___________________________________
SIGNED ____________________________
Page 227 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 8
Installation Of Wire Rope Double Saddle Grips
Wire rope grips are widely used for making end terminations. Grips are available in two basic designs U-bolt and fist grip. SMEP do not allow the use of U-grips (Bulldog grips) to be used but allow properly designed rope grips with two saddles i.e. fist grips.
Fist Grip When making up a sling or termination, always ensure that: a. Never use fewer than the number of clips recommended in Table 1 b.
New clips are used; used clips do not have the full holding ability
c.
A thimble is inserted in the eye of the sling; this prevents the rope from wearing and deforming
d.
The clips are fitted in accordance with the manufacturer’s instructions
e.
All threads and nut bearing surfaces are greased, unless manufacturer’s instructions state otherwise
f.
Full recommended torque settings are achieved, e.g. 49Nm for 16mm diameter rope
g.
A record is kept of measured torque values when terminations are first made and during each subsequent periodic check
h.
Periodic checks of torque settings are carried out as specified below:
as soon as the service load is hung on the rope
after 24 hours in service
after 7 days in service
after 1 month in service
at 6 monthly intervals from the date of installation Stage 1 Turn back specified amount of rope from thimble or loop. Apply first grip one base length from dead end of rope. Tighten nuts evenly, alternating from one nut to the other until reaching the recommended torque.
Page 228 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Stage 2 Apply the second grip as near the thimble as possible. Turn nuts firmly but do not tighten. Stage 3 Apply the remaining rope grips equally between the first two Stage 4 Apply tension in direction of the arrow, and tighten all nuts to the recommended torque. Remember to check the nut torque after the rope has been in operation. To determine the correctly number of grips to be used for specific diameters of rope refer to table 1 Rope Diameter (mm)
Minimum Number of Clips
Rope Turn Back From Thimble (mm)
Torque Un-lubricated Bolts (ft-lb)
5
2
100
30
6
2
100
30
8
2
130
30
10
2
133
45
12
2
165
65
13
3
280
65
14
3
350
130
14
3
400
130
20
3
450
225
22
4
660
225
25
5
940
225
28
5
1000
360
30
6
1400
360
35
6
1600
500
40
6
2000
500
Table 1 Installation of Double Saddle rope grips (Fist Grips)
Page 229 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 9
Shackle – Split Pin Sizes
Safety shackles are widely used for terminating sling set on to containers. Safety shackles are available in two basic designs Bow (anchor) and Dee (chain). It is important that the correct diameter and length of split pin is used, the table below details the recommended size of split pin.
SHACKLE WLL
SPLIT PIN SIZE
0.5 te
2 x 20 mm
1 te
3 x 20 mm
1.5 te
3 x 20 mm
2 te
3 x 25 mm
3.25 te
5 x 30 mm
4.75 te
5 x 30 / 35 mm
6.5 te
6 x 35 / 40 mm
8.5 te
6 x 45 / 50 mm
9.5 te
6 x 45 / 50 mm
12 te
6 x 50 / 55 mm
13.5 te
8 x 55 / 60 mm
17 te
8 x 55 / 60 mm
25 te
10 x 70 mm
35 te
10 x 80 mm
55 te
10 x 100 mm
85 te
10 x 110 mm
120 te
13 x 110 mm
Page 230 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 10
Overload Protection and Anti-Two-Block Requirements
The table shows the overload protection, anti-two-block cut-out, radius or angle indicator and boom length requirements for lifting equipment. Equipment Type
Radius or angle indicator
Boom length indicator
M
M
M
M
M
M
M
M
M
R
M
M
M
Mobile Cranes – Capacity less than 3 tonne Mobile Cranes – Capacity more than 3 tonne Offshore pedestal Cranes Fixed boom length Fixed Capacity Offshore pedestal Cranes Fixed boom length Variable Capacity Offshore pedestal Cranes telescopic boom Fixed Capacity Offshore pedestal Cranes telescopic boom Variable Capacity Offshore Swing Jib Cranes Fixed boom length – Any Capacity Overhead Travelling crane Any capacity (1) Lorry loading crane - Any capacity (2) Forklift trucks Any capacity Key
1. 2. 3.
M R
Antitwoblock cut-out
Rated Capacity Indicator (RCI) or ASLI
M
M
R
M
M
M
M
M
M
Overhoist limiter
Lower hoist limiter
M
R
R
M
M
Load moment limiter or cut-out
M
M
M
M(3)
M R
R
Not applicable on manually operated overhead cranes For telescopic or straight boom cranes only. This does not apply to articulating (knuckle) boom cranes. Only where the crane has a hoist winch Mandatory Recommended
Page 231 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Appendix 11
Glossary of Terms
Alpha/numeric
A combination of letters and/or numbers used for identification.
Anemometer
Instrument (used on some cranes) for measuring wind speed.
Angle Factor
The factor by which the WLL of a multi-legged slings is derated to give its SWL at a particular angle between the sling legs.
Angle Indicator
A device that shows the angle at which the crane boom is operating and the corresponding rated capacity.
Anti-Two Block
See Upper hoist – limiting device.
Approved
Approved by SMEP Technical Authority
Asset Owner
Entity that owns lifting equipment. Either SMEP or Contractor.
Automatic Safe Load Indicator (ASLI) or Rated Capacity Indicator (RCI) A device that automatically provides, with a specified tolerance, warning the load is approaching the rated capacity, another warning when capacity is exceeded. Auxiliary Hoist
A second(ary) lifting system, usually fitted to cranes, operating from a separate winch drum from the main hoist rope. Usually used on cranes to lift light loads, relative to the crane’s capacity, faster than is possible on the main hoist system.
Back Hooking
A method of slinging using slings with hooks where the sling is passed around the load and the hook is secured back onto the ring or hook above the load.
Back Splice
A splice in the end of a fibre rope to prevent it from unlaying.
Banksman/Signaller/Flagman
Person positioned so that he has an unrestricted view of the load and is also in view of the crane driver, so that he may give load-manoeuvring instructions to the crane driver via hand signals or hand-held radio.
Barang Box
A box carrying general goods. A term widely used in Malaysia.
Barge List Or Heel Or Trim
Cause swing out of the load and can produce side load.
Barge List and Crane List
These are not the same. As the crane rotates on the barge, it’s list (as defined above ) will change. The worst crane list condition occurs when the crane slews over the barge’s corner producing maximum side load
Basket Hitch
A method of securing a sling around an object by bringing both eyes back together with an angle factor = 2.
Becket
An anchorage point on a sheave block when reeving a tackle to purchase.
Page 232 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Becket Load
The load in any fall of rope in a multiple fall tackle. It equals the total load being lifted divided by the number of falls supporting the load.
Bilingual Text
English and Bahasa Malaysia
Blind lifts
Lifting operation whereby the lifting appliance operator does not have a direct view of the load or landing area NOTE Use of closed circuit television monitoring the work area is not considered to be direct view.
Billy Pugh
The trade name of the offshore rope personnel transfer carrier in common use.
Block
A hook sheave and frame assembly attached to a rope used for raising and lowering loads.
Block and Tackle
A sheave block or blocks used with fibre rope
Boom
A steel lattice, or steel box section structure that is attached from which the load is suspended and which can be raised or lowered, usually a form of lifting mast.
Boom-Type Elevating
A powered telescopic device, hinged device or
Work Platform
articulated device or any combination of these used to support a platform on which personnel, equipment and materials may be elevated to perform work. Also known as “cherry pickers”
Booming/luffing
The movement of a crane boom from one angle to another in the vertical plane.
Bow Shackle
A shackle with bowed sides.
Bulldog Grip
A wire rope grip consisting of a U-bolt, two nuts and a saddle, usually used to clamp two wire ropes or the same parts of a wire rope. Commonly used for making end terminations NOT ALLOWED WITHIN SMEP.
cm
Symbol for centimetre. 10mm equals one centimetre. 100 cm equals 1 metre.
Calibration
The calibration of test equipment must be in accordance with BS EN ISO 7500-1 or an equivalent standard. Accuracy of calibration in all cases must be within ±2% on the nominal load/force.
Cantilever Beam
Section of beam supported at one end only.
Cargo
Any liquid, solid or gaseous matter transported in an offshore container.
Centre of Gravity
Point at which the total mass of a body may be regarded as being concentrated, or about which the parts of the body exactly balance each other.
Certificate of Inspection or Test Certificate A Certificate of Test issued by the third party certification authority surveyor on completion of a satisfactory survey. A new Test Certificate will require to be issued if the equipment
Page 233 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
is subject to repair or modification. Where a Test certificate states that it is also a report of thorough inspection/examination it must contain all of the information as required by LOLER 98, Schedule 1. Certificate of Compliance
A document in which the manufacturer certifies that the products supplied comply with the requirements of the purchase order, without mention of any test results.
Certificate or Declaration of Conformity
A document in which the manufacturer or other responsible person with legal duties of a manufacturer and who controls the technical file , confirming that an item to which it refers complies fully with an applicable standard and that all essential safety requirements have been met in full. It must give the following information:I. II.
The business name and full address. The responsible person
III.
Where that person is not the manufacturer e.g. a importer, that of the manufacturer.
IV.
A full description of the equipment including make and type and serial number.
V.
VI. VII.
Indicate all of the relevant provisions with which the item complies. Specify the standards and technical standards used. Identify the person authorised to sign the certificate on behalf on the responsible person.
Chain Block
A geared portable appliance used for hoisting and lowering a load suspended on a chain.
Cherry Picker
See Boom-type elevating work platform.
Choke Hitch
A method of securing a load to a sling or a sling to an anchorage by reeving the sling back through its eye, or fixing the eye back to the sling leg with a shackle.
Classification Society Surveyor
A person from a classification society who has the appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly inspected as will enable them to detect defects or weaknesses and to assess their importance in relation to the safety and continued use of the lifting equipment.
Circumference
The distance around the outside edge of a circle.
Clevis
An eye with a removable pin.
Colour Code
A method of marking equipment (normally with plastic tiewraps or paint) to give a visual indication of its certification/inspection status. This 'coded' colour is changed every six months.
Come-Along
See Ratchet lever block
Page 234 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Container
Any form of unit or device used for the transportation of cargo.
Crane
An appliance intended for raising and lowering a load and moving it horizontally, but excluding industrial lift trucks earthmoving machinery and lifts.
Crane Chart
See Load chart or Capacity chart.
Crane Operator or Driver
The person who is operating the crane for the purpose of positioning loads.
Crane, Crawler-Mounted
Except for the base these cranes are identical to the CarrierMounted
Crane List
As the crane’s out-of-level condition, from side to side, as measured by the angle between horizontal and a line drawn through the centreline of the crane’s boom heel pins. This outof-level condition creates side load and effects the crane’s lifting capacity.
Cross Hauling
Process of moving a load in a direction other than vertical, for purposes of access/egress (sometimes called Fleeting). This action is usually carried out using chain blocks and pull lifts and the equipment used is down-rated.
Documented Training
Training whereby it can be documented that the person who will use the lifting equipment has received practical and theoretical training that provides knowledge about its structure, operation, applications, limitations and scope of use, as well as maintenance and inspection in accordance with the requirements set for safe use and operation stipulated in regulations and instructions for use
Drawn-up Dimension
The minimum distance between the suspension level and the bottom hook saddle (also known as closed-height).
Dead end
The tail of a rope which does not take load.
Dee Shackle
A shackle with parallel sides, resembling the letter D on its sides.
Diameter
The distance across a circle measured through its centre.
Diverting Sheave
A sheave set up to change the direction of the lead rope between the winch and the head sheave.
Double Wrap
A method of slinging where the sling legs are passed twice round the load with the eye chocked back to the sling.
Dunage
Packing under loads.
Effective Span
The distance between the centres of the adjacent supports, due allowance the end fixing, continuous beams and cantilevers.
Effective Working Length (EWL) The distance between the extreme inside ends of the eyes in a straight sling. Effort
The pull on the hand chain or lever required to lift a specified load (chain blocks and pull lifts). The specified load is usually the working load limit of the block.
Page 235 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Elevating Work Platform
A telescopic device scissor device or articulating device used to support a working platform.
Elevator
A lifting device, with hinged doors and a fast-releasing latch, which hangs on long links below the travelling block and hook, and which, in a closed position fits snugly around the drill pipe or casing, to handle lifting or lowering of a string.
Elevator Link
A long steel link, which connects the elevators to the main hook.
Equalising Beam
A lifting beam, which can be used with two cranes to ensure that each crane is supporting its correct portion of the load.
Equalising Sheaves
Sheaves used to equalise the load.
Eyebolt
A lifting ring fixed to a thread rod, which can be screwed into a load or anchorage.
Examination
A visual examination by an independent third party surveyor carried out carefully and critically and supplemented by other means, such as measurement and where necessary nondestructive testing, in order to arrive at a reliable conclusion as to the condition and safety of the lifting equipment. If necessary for the purpose, parts of the lifting equipment shall be dismantled.
Extended Dimension
The distance between the suspension level and the bottom hook saddle of a chain block, when the bottom hook is in the extended position. It equals the sum of the drawn up dimension and the range of lift (or height of lift).
FIBC
Flexible Intermediate Baulk Container, commonly known as big bags.
FMEA
Failure Mode Effect Analysis.
Factor of Safety
The ratio of the load that would cause failure of an item of lifting equipment to the load that is imposed upon it in service i.e. SWL (This is to allow for detrimental criteria such as wear and tear, dynamic loadings etc).
Falls
The passes of a rope in a winching/pulley system.
Ferrule/Swaged fitting
A metallic fitting, which wire rope can be inserted and then permanently attached using radial pressure (swaging) the sleeve that enclosed the rope to form an eye.
Fit-for-purpose
Equipment free from defect and used only in the manner for which it was designed.
Fist Grip
A wire rope grip consisting of a two saddles and two nuts, usually used to clamp two wire ropes or the same parts of a wire rope. Commonly used for making end terminations.
Fixed Lifting Equipment
Lifting equipment permanently installed on a Platform normally located at the same point on the Platform throughout the life cycle of the Platform (e.g. pedestal cranes, gantry cranes, swing jib cranes, runway beams, beam, padeyes etc).
Page 236 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Fleet Angle
The angle formed from the centre line of the drum to the centre of the first lead sheave then back to the inside centre of the drum flange.
Fleeting
A method of moving an object by using two hoists, tackles to lift, haul and lower the load.
Flemish Eye
A method of forming an eye in FSWR by separating and remarrying the strands without tucks.
Fly Jib
A secondary jib mounted at the head of the crane’s main boom or jib, increasing the crane operating radius. Also know as “goose neck”
Forerunner
See Pennant
Frame
The primary load bearing elements of a container.
Free Fall
A boom or hook-block descending under its own weight, or that of the load.
Free on Wheels
Able to lift load with a wheeled crane without utilizing the outriggers or stabilisers.
Frog
The trade name of the buoyant enclosed personnel transfer capsule marketed by Reflex marine. Which, is a conical shaped solid cage with three seats, designed for the aerial transport of personnel by an offshore crane.
Functional Testing
Operation of each motion of the lifting equipment without a load applied in order to determine whether the equipment performs as the manufacturer intended.
FSWR
Flexible Steel Wire rope
Gantry
Elevated structure supporting the track of an overhead travelling trolley or crane.
Gin Wheel
A purpose-designed single-sheave tackle block.
Girder/Beam Clamp
An appliance designed to be fixed to the lower flange of a universal beam or RSJ to provide and anchorage for a sing, suspension rope or tackle.
Goose Neck
See Fly Jib.
Grommet
An endless sling constructed with a sling rope strand layed up onto itself.
Gross Weight (containers)
The maximum allowable weight of a loaded container, at the design sling angle, i.e. the Tare weight (weight of empty container) plus the Pay Load (maximum weight of cargo, that can be carried by the container).
HAZID
Hazard Identification
HAZOP
Hazard and Operability Analysis
HEMP
Hazard and Effects Management Process. The structured hazard analysis methodology involving hazard identification, assessment, control and recovery, and comparison with
Page 237 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
screening and performance criteria. To manage a hazard completely requires that all four steps must be in place and recorded. HIP
Hazard Identification Plan – A document that identifies possible hazards and the actions necessary to minimise risk.
Hammer Locks
An attachment for joining hooks or rings to a chain.
Hand Operated Chain Hoist or Chain Block
A block reeved with a load chain and operated by a hand chain so as to give a mechanical advantage (also known as a chain block).
Headache Ball
A spherical overhauling weight attached to single fall hoist above the hook block.
Headroom
The maximum vertical distance between the item to be lifted and the point of suspension of the hoisting machine. e.g. between the lifting padeyes and the underside of runway beam.
Height of Lift
The amount of possible travel between the top and bottom connection points (e.g. hooks) of a hoisting machine.
Hook Block
The lower block on a crane, which incorporates a hook for sling loads.
Hook Load
The total weight suspended form the hook.
Hoisting
Raising or lowering a load
Inertia Forces
The forces produced by a change of velocity.
Inspection
A visual inspection by a an independent third party surveyor carried out carefully and critically for anything which may impair the safe operation of the lifting equipment.
Inspector
The term inspector is used to describe any person carrying out NDT inspection on lifting equipment. In all cases, the inspector shall have experience and training suitable to the NDT inspection being performed.
Jack
An appliance, which is placed under a load to raise or lower it.
Kg
Kilogram
Kinking
Damage to a rope indicated by sharp permanent twist.
Kilogram
A unit for measuring mass (or weight) One litre of water weighs one kilogram. here are 1000kg in a tonne.
Kilo Newton
A unit for measuring force. One kilo Newton is approximately equivalent to a weight of 100kg
Langs Lay
A construction method for FSWR where the wires in the strand and the rope strands are laid in the same direction.
Page 238 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Lattice Boom Crane
A crane with an open-web boom, usually in sections. Normally of a fixed length and cannot telescope.
Lay
The way a rope is constructed.
Left Hand Lay
A method of rope construction where the strands are laid up in an anti-clockwise direction. Sometimes called an ‘S twist’ because the strands run the same direction as the central part of the letter S.
Lifting Appliances
Lifting appliances (overhead cranes, winches, chain hoists, etc but excluding haulage apparatus).
Lifting Tackle Inspector
A person from a third party certification authority who has the appropriate practical and theoretical knowledge and experience of the lifting tackle to be thoroughly inspected which enables them to detect defects or weaknesses and to assess their importance in relation to the safety and continued use of the lifting tackle.
Lifting Tackle or Lifting Accessory or Lifting Gear Any item whatsoever, which is used or designed to be used directly or indirectly to connect a load to a lifting appliance, a crane or chain block etc, and which does not form part of the load, but which is not itself able to lift or lower a load, e.g. slings, shackles, eyebolts, etc. Lifting Equipment
A generic term covering all equipment used to lift and lower a load.
Lifting Operation
A task concerned with the lifting and lowering of a load. It includes the selection attachment and use of suitable lifting equipment.
Lifting Point
Generic term for the certified point(s) or attachment(s) on an item of plant, by which it can be lifted safely. The term also applies to points or attachments fixed to structural members and from which a load can be suspended. For example lifting lugs, lifting eyes, trunnions, fabricated lifting plates, padeyes and jacking points.
Lifting Plan
A document produced by the lift planner to describe how the lifting operation should be carried out, including any contingency plan if the operation becomes interrupted (e.g. because of weather change, break down etc.)
Lift Planner
A person who has appropriate practical and theoretical knowledge and experience of the lifting operations to enable them to prepare a full working lift plan.
Lifting Set/Sling Set
Lifting slings and shackles used to connect a container to the lifting equipment.
Lifting Technical Authority
The Lifting Technical Authority is responsible for assuring the technical integrity of an operational facility, in the context of this document this covers approval of this document, and deviations from this document.
Live Loads
Any load, except wind load, that gives rise to a variation of stress in to a crane. Such variation may be due to any change of position or magnitude of an externally applied load, or to the movement of the crane structure itself.
Page 239 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Load Line
A wire rope suspending a hook.
Load Chart
A manufacturer’s notice fixed to a crane or hoist, which specifies the SWL’s in all normal operating configurations.
Load Factor
The fraction of a sling assembly’s WLL created by a particular sling method. It includes the angle factor and the reeve factor.
Load Weight Indicator
A device, which indicates the weight of the load being lifted.
Lorry Loading Crane
A powered slewing crane mounted on a vehicle for the principal purpose of loading and unloading the lorry.
Luffing
See Booming.
M
The symbol used to indicate the diameter of a structural bolt in millimetres. For example, M16 indicates a 16mm bolt.
m
A metre – the unit for measuring distance - 1000m equal one kilometre.
mm
Millimetres – the unit for measuring distance - 1000mm equal one metre.
MOU
Mobile Offshore Unit.
Manila
Sisal, A natural fibre used for rope construction.
Marlin Spike
A tapered hand tool used to pry open the strands on an FSWR during splicing or during rope inspection.
Marine Vessel
For the purposes of this document, marine vessel shall be interpreted as meaning:Barge (towed) Barge (self propelled) Pontoon Pipe Laying Barges Cargo Barge Work Boat Crane Barge
Measured Deflections
The deflections measured in such a manner that they relate to precisely the same conditions as those covering the calculated deflection.
Mechanical Advantage
The ratio between the load raised and the effort required to raise it.
Mobile Crane
A crane which can travel over a supporting surface without the need for fixed runways or railway tracks and which relies on gravity for stability.
Mode Factor
A factor, which takes into account the geometry of the sling assembly, the number of parts and other constants as specified in the appropriate British Standard.
Multi-Legged Sling
A sling assembly with more than two sling legs.
Page 240 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Multiple Crane Lift
The movement of a load where the load is suspended from two or more cranes.
NDT
Non-Destructive Testing.
Net Capacity (Cranes)
The net capacity is determined by deducting the crane capacity deductions from the crane’s gross capacity. The deductions differ from manufacturer to manufacturer as well as between crane types. Deductions normally are: Weight of main hook block Weight of slings and rigging Weight of auxiliary hook block Weight of all wire rope from boom tip and the block Weight of any stowed jib
Non-Destructive Examination (NDE) The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect, locate, measure, and evaluate flaws; to assess integrity, properties, and composition; and to measure geometrical characteristics. Non-routine Lift
A lifting task that is of greater complexity than a routine lift, such that it requires specialist resources and guidance and special procedures written to enable its safe completion. These lifts are normally subdivided into simple, complicated and complex lifts.
Offshore Container
Transportable unit for repeated transport of load or equipment, a unit that can be handled in open sea to/from installations and vessels NOTE 1 The unit includes equipment for lifting, handling, filling, emptying, cooling and heating etc. NOTE 2 There are two categories of offshore container: 1. Offshore freight container a. Freight container for dangerous goods. b. Freight container for non-hazardous load that is not covered by the IMDG code. 2. Offshore service container Service container produced and equipped for special use, mainly for temporary installation.
Offshore Crane
Slewing crane for general use mounted on an installation and which is used to handle loads to and from supply boats, barges or semi-submersible installations
Operating Level
The level on which the operator stands.
Page 241 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
On Rubber
The operation of a truck-mounted or rough terrain mobile crane without the aid of outriggers.
Ordinary Lay
See Right Hand Regular lay.
Outrigger
A hydraulic stabilising extension for a mobile crane.
Overload Testing (Static)
Operation of the lifting equipment with a load exceeding the rated load but without operating the full range of motions of the equipment in order to determine whether the equipment is stable, structurally sound and fit for the use for which it was designed.
Overload Testing (Dynamic)
Operation of the lifting equipment, in all possible motions with a load that exceeds the rated load applied in order to determine whether the equipment is stable, structurally sound and fit for the use for which it was designed.
Payload
The maximum permissible weight of cargo which may be safely transported by the container.
Parts of Rope
See ‘falls’
Permanently Attached Slings Sets Permanently Attached Slings Sets are used only for transportation of containers. They must not be used for general lifting duties. These slings are colour coded Purple with a band of the current colour code. Permissible Working Stress
The stress numerically equal to the basic stress, multiplied by the relevant duty factor corresponding to the load.
Performance Testing
Operation of each motion of the lifting equipment with the rated load applied in order to determine whether the equipment performs to the manufacturer’s specification.
Person In Charge (PIC)
Person who is approved by SMEP’s Lifting Technical Authority to be in charage of a lifting operation.
Personnel Carrier
Carrier designed for the aerial transport of personnel usually by an offshore crane “FROG” or Esvagt.
Billy Pugh -
A personnel transport device composed of a solid cylindrical platform, flexible sidewall rigging, lift cumulator ring and lifting loadline system designed for the aerial transport of personnel by an offshore crane. (Not used in SMEP)
Pendant
A rope used to provide support to length of a crane boom or jib.
Pennant/Stinger
A single wire rope sling with an eye on one end and a hook on the other usually suspended from the crane’s hook. Sometimes called a extension sling or forerunner.
Pendant Control
A hand-held set of motion controls attached to a crane or hoist by an extension cable to provide operation. Particularly used with some types of overhead travelling cranes and powered-operated chain blocks.
Plant
Generic term covering, machines, sub-assemblies and structures.
Page 242 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Plant/Identification Number
A unique number given to an item of lifting equipment or registration purposes and to facilitate traceability.
Plate Clamp
A purpose designed item of equipment for lifting steel plate and similar items, usually used in pairs.
Portable Lifting Equipment
Lifting equipment, which can be transported from one part of a platform to another or between different platforms. (chain blocks, lever hoists, beam clamps, Tirfors, etc)
Proof Load Test
A test load (mass or force) applied to an item of lifting equipment/accessory to prove its integrity. Proof load tests can be carried out to various standards, but results must be recorded on a Test Certificate.
Pre-Use And Post-Use Check
Visual and functional assessment (not test) of the lifting equipment’s technical condition before and after use (without disassembly)
Pulley (or Sheave)
A grooved wheel over which a rope passes. Pulleys are usually shaft mounted and free to rotate in response to movement of the rope.
RCI
Rated Capacity Indicator.
Rotation Resistant (RR)
FSWR in which adjacent layers of strands are laid in opposite directions, i.e. alternative right hand and left hand to prevent the rope from spinning under load. Commonly used as a crane hoist rope, sometimes called non-rotating rope.
Radius (Slewing Cranes)
Horizontal distance between the point at which the centre of rotation meets the ground and the vertical centreline passing through the load lifting attachment
Radius (Non-Slewing Cranes)
Horizontal distance from the centreline through the load lifting attachment to the nearest axle or track measured at ground level.
Radius Indicator
A device that shows the radius at which the crane boom is operating and the corresponding rated capacity.
Range of Lift
The vertical distance that the bottom hook travels between the extended and highest positions.
Ratchet Lever Block
A geared portable appliance incorporating a load chain, which is operated by a lever handle.
Rated Capacity Limiter
A device that automatically provides, with a specified tolerance, motions that could increase risks, if the rated capacity is exceeded.
Rated Capacity Indicator
See ASLI
Responsible Person
Refer to Person in Charge (PIC).
Reeving (crane)
Configuration of the hoisting rope in a winching system.
Reeving (rigging)
A method of slinging where the sling passes back through itself reducing the safe working load.
Rigging
The use of mechanical load shifting equipment and associated gear to move, place or secure a load including plant,
Page 243 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
equipment or members of a building or structure and to ensure the stability of those members and for the setting up and dismantling of cranes and hoists, other than the setting up a crane or hoist which only requires the positioning of integral outriggers or stabilisers. Rigging Screw or Turnbuckle
An enclosed device with an anchorage point and threaded rod in each end. Used to tension an FSWR or to provide fine adjustment to a sling assembly.
Rigging Store
An offshore container, or similar, modified specifically to suit the storage of lifting equipment (often equipped with lighting and heating).
Right Hand Lay
A method of rope construction where the strands are laid up in a clockwise direction. Sometimes called a ‘Z twist’ because the strands run in the same direction as the central part of the letter Z.
Risk Assessment/JSA
Job Safety Analysis (JSA) is the application of the hazards and effects management process at the task level, identifying and assessing the hazards of each element of the task and defining appropriate controls and recovery measures. The methodology is derived from the work study technique known as Task Analysis, and is known variously as Job Hazard Analysis (JHA), Work Safety and Health Analysis, Activity Risk Assessment (ARA). Refer E95 – 0311
Rigger/Slinger
The person responsible for attaching and detaching the load to and from the crane and for correct selection and use of lifting tackle.
Rolled Steel Joist (RSJ)
A structural steel member with an I-section, now largely superseded by the universal beams (UB’s).
Rough Terrain Crane
Short wheel based mobile crane designed to operate on unimproved natural terrain and disturbed terrain of construction sites, with crab steering, and fitted with oversized tyres to facilitate travel across rough terrain.
Round Sling
An endless synthetic fibre sling constructed with a circular cross section.
Routine Lifts
Those lifts undertaken on a day-to-day basis that are fully addressed by existing 'generic' training and competence procedures.
Runway Beam
An overhead structural beam certified to a specific SWL and used for the attachment of lifting equipment, such as trolleys, beam clamps, etc.
SLI
Safe Load Indicator.
Safe Working Load (SWL)
The maximum load (as certified by an independent competent person), which an item of lifting equipment may raise, lower or suspend under particular service conditions.
Serving/ Sizing or Whipping
The binding, in wire or twine, at the end of a rope to prevent the strands from opening or fraying.
Page 244 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Sling Assembly
A sling in the form in which it is actually used.
Soft Eye
An unsupported loop, i.e. is not protected by a thimble, and formed at the end of a rope to facilitate connection of a lifting device.
Sheave
A grooved wheel over which a rope passes over.
Sheer legs
A derrick like appliance consisting of two legs in an ‘A’ formation, with sheave block fixed to its apex and in a framework.
Sisal
Vegetable fibre obtained from the sisal plant. Sometimes used to construct natural fibre ropes.
Significant Wave Height
Average height of the highest third of prevailing waves, typically measured over a period of three hours. NOTE As a rule of thumb, significant wave height is about half the maximum wave height.
Slewing
The left and right movement of a crane boom pivoting on its base in the horizontal plane.
Sling
Detachable lifting gear made from FSWR, chain or synthetic fibre.
Sling Angle
The angle the sling makes with the horizontal. Maximum allowed is 90º included angle or 45º to the vertical.
Snatch Block
A single pulley sheave block with a drop side plate to allow easy access to the pulley wheel for rope attachment or removal without reeving it through.
Spreader Bar/Beam
A beam/bar with a central lifting attachment and with slinging points at each end. Used to reduce the angle of slings or to sling loads with large surface areas or to reduce the strain on load.
Stinger
See Pennant
Strand
A number of wires or fibres laid in a spiral, which is laid up with other strands to form a rope.
Strop
An endless sling.
Structural Integrity
The reliability of the load bearing structure.
Statement of Conformity
A statement issued by the manufacturer confirming that any necessary manufacturing tests have been carried out, and confirming the SWL. The statement has the same status as a test certificate and must be retained for inspection when required.
Surveyor
A person from a third party certification authority who has the appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly inspected as will enable them to detect defects or weaknesses and to assess their importance in relation to the safety and continued use of the lifting equipment.
Page 245 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Swaged Fitting
See Ferrule.
Swivel
A rotating item of lifting gear, which can rotate without spinning the rope, hook or load.
Synthetic Fibre
Manufactured fibre used in the construction of fibre ropes and slings, such as polyamide (nylon), polyester, polyethylene, polypropylene etc.
T
Symbol indicating Grade 80 chain.
te
Symbol for tonne. (1000kg)
Tank Container
A container that consists of the tank or tanks, and the load bearing structure.
Tagline
A fibre rope attached to a suspended load to control the load during lifting.
Tare weight
The weight of the container without cargo. Tare weight shall include all fixtures normally fixed to the container in service.
Telescopic
The extension or retraction of a crane’s boom or jib by the movement of the boom or jib sections during normal operation. A feature of most hydraulic boom cranes.
Test Certificates
A Test Certificate is the certificate of a proof load test, which would normally be carried out at the completion of manufacture and be supplied with the equipment. A new Test Certificate may require to be issued if the equipment is subject to repair or modification, or if the independent competent person deems it is necessary to ensure continuing integrity.
Test Load
Specified load that the lifting equipment shall withstand within the manufacturer’s specified limits without resulting in permanent deformation or other defects, and thereby confirming that the design, materials and manufacture comply with specification and statutory requirements
Thimble
A grooved piece of metal, circular or pear-shaped, used to protect an eye splice. It forms a ‘hard eye’
Thimble Eye
A loop formed at the end of a rope around a supporting metal eye, i.e. the thimble.
Thorough Examination
A visual examination and certification of lifting equipment carried out by a surveyor from an third party certification authority in accordance with IMP 0.03 Lifting Equipment SMEP.EP72.ST.0032 and any subsequent amendments thereto. The inspection carried out by the surveyor shall carefully and critically, supplemented by other means, such as measurement and where necessary non-destructive testing, in order to arrive at a reliable conclusion as to the condition and safety of the equipment. If necessary for the inspection, part of the equipment shall be dismantled. The surveyor shall be independent of the supplier of Lifting Equipment.
Ton (T) or long ton
For the purposes of the lifting equipment management documents, one long ton shall be interpreted as 2240 pounds, which is 1016 kilograms.
Page 246 of 247
Shell Exploration & Production, ASIA PACIFIC
S M E P . EP200802258279
SMEP LIFTING AND HOISTING MANUAL
REV.1.0
Ton (short) or US Ton (T)
For the purposes of the lifting equipment management documents, one short ton shall be interpreted as 2000 pounds, which is 907.18 kilograms.
Tonne / metric ton (te)
For the purposes of the lifting equipment management documents, one tonne shall be interpreted as 1000 kilograms.
Toolbox Talk
A short discussion held between all members of a lifting operation prior to commencement of work in order to agree on all aspects of the work and the sequential steps to be taken to complete the work. The agreed procedure, hazards and control methods are to be recorded.
Transit Slings
Transit slings are used only for transportation of equipment to and from offshore platforms. They must not be used for general lifting duties, however they can be used to return an item of equipment onshore.
Trigonometrical Method
A method traditionally used to calculate the SWL of slings with the sling legs at various angles.
UB
Universal Beam
Upper Hoist – Limiting Device
A device used in a crane or hoist to stop the winch or warn the operator before the hook block jams into the head block (two-blocking) while the hook is being raised.
Universal Beam (UB)
An I section steel beam commonly used in steel structures.
Uniform Load Method
A method of rating multi-legged slings for use at any included angle between the sling legs of up to 90° and 120°. This is the preferred method for rating general-purpose slings.
Velocity Ratio
The ratio between the velocities of a chain block hand chain and the load. It is equivalent to the number of metres of hand chain overhauled to raise the load a distance of one metre.
WLL
Working Load Limit.
Warning Beacon
A lamp that is capable of emitting a flashing or rotating beam of light through 360º in the horizontal
Winch
A stationary motor driven or hand powered hoisting machine having a drum around which is wound a rope used for hoisting, lowering or pulling a load.
Wind Load
The forces produced by the velocity of the wind, which is assumed to act horizontally.
Webbing
A part of a lifting sling, either flat or round, comprising a woven narrow fabric, generally of a coarse weave and multiple plies, the prime function of which is load bearing.
Whipping
See Serving.
Working Load Limit (WLL)
The maximum load, which an item of lifting equipment is designed to raise, lower or suspend as stated by the equipment manufacturer.
Page 247 of 247
