Lifting & Hoisting Procedure

Transcription

1 AL-Yamama Engineering Company HSSE Department (s) Lifting & Hoisting Contents 1. Objective Error! Bookmark not defined. 2. Scope 1 3. Risk domain and risk 1 4. Activity Responsibility Matrix 1 5. Related controlling documents 4 6. Other references Error! Bookmark not defined. 7. Definitions 4 Appendix 1 10 Questions for a Safe Lift 6 Appendix 2 7 Appendix 3 Lifting Categories 8 0

2 1. Scope This applies to all aspects of L&H activities using pedestal cranes, mobile cranes, overhead and gantry cranes, A-frames, jib cranes, derricks, hoists, and special hoist-supported personnel lifting devices. This Specification does not apply to elevators (lifts) in buildings, jacking, diving operations, well operations involving the crown block, travelling block, and top drive systems, mining and earth moving, lumber (timber) logging, mobile work platforms, vehicle maintenance lifts, helicopter lifting, operation by piling machines, and manual lifting. 2. Risk domain and risk Risk Domain(s) Objects Overhead, Objects under Tension Crushed by fallen objects Risk(s) 3. Activity Responsibility Matrix Task Work Requestor Field/ Construction Manager HSSE&SP Advisor Person in Charge PIC SME for L&H Emergency Response Coordinator L&H Team PtW Requestor Remarks 1 Identify activities and determine scope of work Exe Inf Inf 2 Appoint Person in Charge Exe Inf Inf Identify Hazards and L&H Category Develop & appoint L&H team Assess Emergency Response Arrangements Con Exe Inf Inf Con Exe App Con Con Exe Inf 6 Request Permit to Work Inf Inf Inf Exe Mobilise L&H Equipment to worksite Communicate Lift Plan and conduct Pre-Use- Inspection Conduct L&H activity De-Mobilise L&H Equipment from worksite Inf Inf Chk Exe Exe Chk Inf Exe Inf Inf Chk Exe *1 for High Risk Derogations only Exe Execute: responsible to do it or get it done Con Consulted: on task and results; only as necessary App Approve: accountable, must sign off on results Inf Informed: about tasks and results Chk Check: plus provides support to the responsible party 1

3 Additional requirements Task 1 Identify activities and determine scope of work Identify activities and determine scope of work. Check if the particular L&H operation has been carried out before on the site as a risk assessment and lift plan might already exist. If they do exist verify that they are still applicable (e.g. no changes to personnel, equipment, site layout or work environment) and request required approval from relevant parties. Task 2 Appoint Person-In-Charge (PIC) The PIC is designated to plan the L&H operation and may or may not supervise the L&H operation but is the focal point of authority for the safety and technical aspects of the operation. Task 3 Identify hazards and L&H category The level of planning and risk assessment increases with the complexity of the L&H operation, therefore: 1. Identify the applicable Hazards 2. Classify the L&H Category using the L&H categories in [Appendix 3 Lifting Categories] 3. Develop control measures as specified in [Appendix 3 Lifting Categories] The Risk Assessment shall address the following but not limited to*: Availability of approved lifting points on load Weight, size, shape and centre of gravity of load Cultural, communication and language difficulties Method of slinging/attaching/detaching the load Overturning/load integrity/need for tag lines Ground and underground considerations Initial and final load positions and how it will get there Suitability and condition of Lifting Equipment to be used Lifting over live equipment Number and duration of lift(s) Access and emergency escape routes for e.g. Banksman, Slinger) Environmental conditions including weather and permissible limits Pre-Use Inspection of equipment by Operator Lighting in the pick-up and lay-down areas Working under suspended loads Number of personnel required for task Experience, competence and training of personnel Conflicting tasks in area Proximity hazards, obstructions, path of load (e.g. potentially live electrical, hydraulic or pneumatic lines, underground conduits, bridges and overhead structures) Visibility of the load at all times by either the Lifting Appliance Operator or the person guiding the load (Banksman). He must maintain communication with the Operator at all times either via hand signals, radio or a relay Signal Banksman. For Routine L&H operations a generic Risk Assessment may be used. Task 4 Develop and appoint L&H team Prepare a using the form in [Appendix 2 ] and identify: The competent person planning the lift Equipment required Personnel required and their particular roles Step-by-step instructions Communication methods to be used Contingency and rescue plans. For Routine L&H operations a generic may be used. For Non-Routine Complex L&H operations the must be approved by an Authorised Subject Matter Expert. 2

4 Appoint the L&H team and ensure that those involved are competent for performing their task. Task 5 Assess Emergency Response Arrangements Identify if the activity doesn t block any emergency routes and if the existing Emergency Response arrangements are sufficient to rescue people involved or affected by the activity. If in non-compliance reassess the L&H activity (see Task 2) and/or develop a dedicated rescue plan. Task 6 Request Permit to Work Request a work permit in accordance with AY Permit to Work [5]. Task 7 Mobilise L&H equipment to site When mobilising the L&H equipment to site verify that: Access roads are strong enough to withstand axle load of mobile L&H equipment, Type of ground can withstand the maximum bearing pressures transmitted through the outriggers The L&H equipment is not erected too close to edge of an excavation or overhead cables. The L&H area is fenced off. Task 8 Communicate and conduct Pre-Use Inspection Prior to starting the L&H operations hold a Toolbox Talk with all personnel assigned to carry out the L&H operation. The 10 questions for a safe lift [Appendix 1] shall be covered during the Toolbox Talk. Ensure that: All personnel involved in the lifting operation have their individual responsibilities clearly allocated. All personnel have the opportunity to review the findings of the risk assessment and the details of the Lift Plan [Appendix 2], Everyone clearly understands and agrees with the methods and control measures to be used, All lifting Equipment meets the requirements of AY Specification Design, Maintenance & Inspection of L&H Equipment [3]. Task 9 Perform the L&H activity Conduct the L&H activity in strict accordance with the approved. Any variation from the agreed must result in the job being stopped and reassessed to ensure continued safe operation. The L&H Operator shall obey an emergency stop signal at all times, no matter who gives it. When lifting operations need to be controlled by signals, a designated signal person shall be assigned. Signals between the Crane Operator and the designated signal person (Banksman / Signaller) shall be audible or visible at all times. Stop L&H activities at wind levels above 6 Beaufort Complete pre-inspection checks - AY Guide Lifting & Hoisting [4] and AY Specification Lifting & Hoisitng of Personnel [3] provide several checklists to be used. Moving the load Prior to lifting the PIC shall be satisfied that the load is secure and properly balanced and that the load path is clear of obstructions and personnel The appropriate load-radius chart for the Lifting Appliance configuration in use shall be visible to the operator. The Load to be lifted shall be confirmed to be within the rated capacity of the Lifting Equipment and attached by means of suitable Lifting Accessories. The Operator of the Lifting Appliance shall not leave the operating controls while the load is suspended. At commencement of the first lift the Lifting Appliance Operator shall carefully check the operation of the hoist brake to ensure no slippage occurs 3

5 Take up sling slack to confirm that the Lifting Appliance hook has been positioned centrally over the load lifting point, adjust the Lifting Equipment as necessary to inimize any drift of the load as it is lifted No external forces shall be applied to the load that create significant side loading of the Lifting Equipment For crane operations appropriate tag lines shall be used to control the load large or long loads with flat sides that could act as a sail are particularly prone to spinning and tag lines shall be used tag lines shall be secured to the load and not to the rigging slings Cranes shall not be used for dragging a load unless properly rigged for a vertical pull No fewer than five (5) full wraps of rope must remain on the winch drum in any operating conditions. Task 10 Demobilise L&H equipment Demobilise equipment, return Work Permit [5] and leave the site safe. 4. Definitions 4 Assessor Authorised Person Authorised Subject Matter Expert Banksman Blind Lift Crane Operator Job Safety Analysis (JSA/JHA) Lift Category Lifted A person who makes judgments of skills and knowledge of a crane driver (operator), slinger and banksman. A person authorised and assigned responsibility to perform work in accordance with AYLifting & Hoisting Handbook. An Authorised Person has Proficiency assured at Skill level for the specified activity. The term Authorised Person is a functional description of the role rather than a job title. The job titles of persons assigned the requirements e.g. Operator, Electrician, Inspector. A person authorised and assigned responsibility to develop and approve s for a specified subject area such as Lifting and Hoisting. An Authorised Subject Matter Expert has Proficiency assured at Skill level and is Accredited at a professional level in the specified subject area, typically with an external qualification such as a degree, certification or licence. The term Authorised Subject Matter Expert is a functional description of the role rather than a job title. Person responsible for relaying a crane movement signal to the crane operator. A lift where at any point in time during the lifting operation the crane operator cannot directly see the load. Person whi is operating the crane for the purpose of positiong loads or operating for erecting of the crane. Note: for mobile cranes, the term operator is often used instead, and the term driver is then used to refer to that person who operates only those controls which moves the crane from place to place Also known as a Job Hazard Analysis (JHA) is a process for discussing and documenting each step of a job, identifying the existing or potential HSE hazards and then determining the best way to perform the job to reduce or eliminate the hazards. The JSA/JHA will typically include: Selecting the job to be analysed; Breaking the job down into a sequence of steps; Identifying potential hazards; Determining preventive measures to overcome these hazards; Identifying the resources required, i.e. manpower and equipment, to execute the task safely. A categorisation of lifting operations (i.e. Routine Lifts and Non-Routine Lifts) reflecting the risk of the lifting operation and the required level of control. The details of how the lifting operations should be undertaken, the Lifting Equipment and Lifting Accessories to be used, how the equipment and Lifting Accessories shall be rigged up and the control measures in place to manage the risks. Any device which is used to suspend the load, including containers, tanks, skips, skids,

6 Equipment Lifting Accessories Lifting Appliances Lifting Equipment Loose Lifting Equipment Management of Change Non- Routine Lifts Pre-use Inspection Person in Charge Of The Lift Personnel Platform/ Carriers Routine Lifts Rigger Safe Working Load (SWL) Suspended Basket Toolbox Talk drum rackets, pipe racks, frames, gas cylinder racks, pallets, flexible industrial bulk containers ( big bags ), tree cages, cargo nets, and cargo baskets. Any device which is used or designed to be used directly or indirectly to connect a load to a Lifting Appliance and does not form part of the load e.g. slings, hooks and fittings, swivels, shackles, eye-bolts, rigging screws, wedge sockets, plate clamps, and spreader beams. Any mechanical device capable of raising or lowering a load, e.g. cranes, forklift trucks, powered hoists, manual hoists, lever hoists, beam trolleys, beam clamps, sheave blocks, winches, runway beams, mono-rail hoist, etc. Lifting Equipment comprises Lifting Appliances (equipment performing the lifting), Lifting Accessories (devices which connect the load to the lifting appliance), and Lifted Equipment. Lifting Equipment that is portable enough so that it can easily be moved or carried by a person(s) to/from a store / location to a worksite to conduct a lifting operation. This may include Lifting Appliances (e.g. manual lever hoists, chain falls, beam clamps etc) and Lifting Accessories (e.g. slings, shackles etc.) A process to ensure that appropriate review, approval, implementation, and tracking is in place to manage changes to the planned activities. All lifts not classified as Routine Lifts. A visual check and, if necessary, a function check of the Lifting Equipment by a competent person before each use. In determining the suitability and scope of the inspection, reference should be made to information such as manufacturer s instructions and relevant industry standards. The person who has overall responsibility for the L&H activity. The Person in Charge plans the lift operation with any personnel to whom responsibility has been delegated, and monitors the development of safety features for lift operations and the lifting operation. A Personnel Platform/Carrier is designed and intended to give access to a work place at height for personnel and their tools and equipment to carry out minor work or inspections at a limited time. The platform is not designed for the actual transfer of personnel or to be used as a hoisting or lifting tool. These are lifts involving loads of known or evaluated weight, shape and centre of gravity. The Routine Lift will be performed in normal environmental conditions (e.g. not in adverse weather) using standard rigging arrangements. Examples of Routine Lifts are loading/offloading supply vessels and vehicles, moving grocery boxes, lifting re-bar, and delivering concrete by skip. Competent person who is able to plan and execute a rigging job by moving the load horizontally, vertically and possibly through different floor levels, by use of different L&H equipment. The maximum load (as determined by a competent person) which an item of Lifting Equipment may raise, lower or suspend under particular service conditions, e.g. the SWL can be lower than, but can never exceed, the WLL. Normally SWL = WLL unless the Lifting Equipment has been de-rated. A device fitted out for the transportation of persons to a workplace at height by attaching the suspended basket using its own hoisting accessories to a hoisting installation (crane). Toolbox Talk, also known as Toolbox Meeting and Tailgate Meeting, is required to be carried out for all work with significant safety exposure. The Toolbox Talk must be done at the work site. It is the final check in the hazard assessment process and the start of the implementation of the work. The Toolbox Talk shall cover the work plan, the hazards, the controls, roles & responsibilities, and any recovery measures to be taken if the controls are not completely effective. 5

7 Working Load Limit (WLL) The maximum load, determined by the manufacturer, which an item of Lifting Equipment is designed to raise, lower or suspend. Some standards and documents refer to WLL as the maximum SWL. Appendix 1 10 Questions for a Safe Lift 1. Is everyone aware of and do they fully understand the lifting and hoisting procedures applicable to the lift? 2. Has everyone attended the toolbox talk? 3. Has a pre-use inspection of the Lifting Equipment been carried out and are the Lifting Accessories tagged or marked with: Safe Working Load A unique identification number A valid certification date 4. Are all safety devices working? 5. Does everyone know the Person-in-Charge of the lift? 6. Is everyone competent and aware of his or her tasks? 7. Is there a current and Job Safety Analysis and does everybody understand the job and precautions? 8. Does everyone know the environmental limits (e.g. maximum permissible wind speed) for the lift? 9. Is the lift area controlled and is everyone clear if the load falls or swings? 10. Are signalling methods and communication agreed and clear to you? 6

8 Appendix 2 7

9 Appendix 3 Lifting Categories ROUTINE OPERATION Routine Crane Operations o Lifting & Hoisting operations that are performed on a regular basis (a routine operation) o Simple operations with a crane o Simple operations with portable lifting appliances o L&H operations by means of a loader crane equipped with a hoist function o Stable load with known and evaluated weight, shape and centre of gravity o Standard rigging arrangements o Repetitive functions with same equipment and with same operators o Lifting over non-sensitive areas o Suitable environmental conditions CONTROL MEASURES Operation Planning Permit to Work Job Safety Analysis (generic) Existing written Controlling Documents for the L&H operations Toolbox Talk NON-ROUTINE OPERATION Simple or basic L&H operations o Using only one L&H appliance o Stable load with known and evaluated weight, shape and centre of gravity o Centre of gravity below the hoisting point o Sufficient working area and ample headroom o Standard rigging arrangements o Not within sensitive, difficult or restricted areas Operation Planning Permit to Work Risk Assessment dedicated to the operation Simple sketch showing operation to be prepared & executed by a competent person Toolbox Talk 10 Questions for a Safe Lift Complicated L&H operations o Using two or more L&H appliances o Tandem lift using cranes and tailing of loads o Hoisting of personnel o Operator has no direct view on the load blind lift o Extended duration, e.g. more than one shift o Odd shape loads, not having centre of gravity in the middle of the load, but with a known weight o Within sensitive, difficult areas Operation Planning Supervision by Person-In-Charge Permit to Work MFD Specification Lifting & Hoisting of Personnel [3] Risk Assessment dedicated to the operation Specific & numbered drawing, showing the operation to be carried out, prepared by a 8 Complex/Critical L&H operations o Heavy lifts (weight of the load > 25ton) o Weight of the load in excess of 90% of the rated capacity of the L&H appliance o Load with unknown, difficult to estimate, weight and or centre of gravity o Special or expensive load, whose loss would have serious impact on production operation o Overactive or energized hydrocarbon-containing process equipment o Hoisting through hatches, small deck openings, in shafts and several deck levels o Non-standard rigging arrangement or equipment Operation Planning Permit to Work Supervision by Person-In-Charge Formal written work package including Method Statement describing the operation Dedicated & qualified engineering input to Method Statement and, by means of numbered drawing(s), clearly & detailed showing all accessories Formal approval of work package and planning by Authorized Subject Matter Expert Risk Assessment dedicated to the operation Toolbox Talk 10 Questions for a Safe Lift