Military reference books and manuals (2009-2023, Volume 4) - page 41
Procedure for Lifting Operations
Page 15 of 55
6.6
Control of Cargo Carrying Units (CCUs)
The Site Manager, Site Controller, or Offshore Installation Manager is accountable for
ensuring a competent person is assigned for verification that all CCUs sent from the site are
in a safe condition and for obtaining of an accurate weight of all CCUs and ensuring that
such weights are not above the SWL.
The weight of each CCU shall be recorded on the outbound manifest and a copy made
available to receiving asset. All CCUs sent to BP operated sites should have a minimum of
one month certification period remaining.
Stacking of containers, baskets, tanks and half heights is generally not allowed on BP sites.
Where this is not practicable, stacking requires prior permission of the relevant BP
Performance Unit Leader (or Vice President in case of Drilling & Completions) and:
¾ Equipment is specifically designed for that purpose, and clearly marked as suitable for
stacking
¾ Stacking is confined to pre-designated areas
¾ Risk assessment of stacking operations is performed and demonstrates the risk
involved is lower than alternative practicable approaches
¾ Stacked containers must have an additional pennant so that the crane hook can be
attached / detached while the load handler is standing at deck level
¾ Stacking and de-stacking is controlled by permit
6.7
Control of Mobile Lifting Equipment
No mobile equipment shall be used unless it has valid certification of Thorough Examination.
6.8
Control of Third Party Contractor Lifting Equipment
Contractor lifting equipment includes all items whether rented, or supplied free of charge, as
part of the contractor tools of trade, including container sling assemblies.
Contractor lifting equipment may arrive on a site by a number of different routes. It is the
Site Lifting Coordinator‟s responsibility to verify that equipment satisfies the requirements of
this SSOW.
The contactor will be responsible for equipment certification and keeping a register for all
lifting equipment which shall be made available for audit as and when required by BP.
6.9
Control of Uncertified Structural Components
Use of these components will automatically classify the lifting operation as Complicated,
unless an approved site / installation specific procedure is in place.
If a rigging plan utilizes an uncertified structural component, it is vital that sufficient data is
collated regarding the component in question. The assessment may require engineering
calculations with regard to stresses and strains that apply to the component in question.
The MHC Technical Support Engineer shall become involved to provide engineering or
technical expertise per the lifting plan decision tree.
Control Tier:
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Document Number: << AZSPU-HSSE-DOC-00056-2>>
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Procedure for Lifting Operations
Page 16 of 55
6.10 Control of Webbing and Round Slings
Use of man made endless fibre round slings and flat webbing slings will automatically default
to the Complicated lifting unless an approved site specific procedure is in place.
A Site Competent Person shall be appointed to inspect these types of slings for damage
prior to use. If damage is evident or suspected, the slings shall be physically removed and
destroyed. Certification for this type of sling is valid for six month only, after which it must be
destroyed.
Man made fiber slings shall not be recertified.
7
COMPETENCY
7.1
Competencies and Training of Personnel
The Site Manager / Site Controller / Offshore Installation Manager shall ensure that all
persons involved with lifting equipment, its use, operation, management, maintenance and
training, have received formal recordable training and experience that provides levels of
competency according to their tasks and responsibilities and at least to the level in the
following chart.
All personnel involved in mechanical handling and lifting operations on Azerbaijan and
Georgia AzSPU Installations and Sites, shall be trained to the relevant standard (North Sea
or equivalent) and formally assessed as competent in the tasks to be undertaken.
Documentary evidence of training and competence assurance will be required before any
person is authorized to perform lifting operations.
The Site Manager / Site Controller / Offshore Installation Manager shall ensure a register of
competent personnel authorized to undertake lifting operations shall be maintained.
Description of Role
Lifting Operation
Level of Competency
Level 1 EAL / ECITB / CITB
Banksman
Routine and Simple
Green Card or equivalent
Rigger / Slinger /
Level 2/3 EAL / ECITB / CITB
Routine and Simple
Load Handler
Blue card or equivalent
Offshore: Sparrows Stage 3
(OPITO) or equivalent.
Onshore: crane operators
shall have the correct
operators licence for the type
Crane Operator
All Categories
of crane they are operating
and shall be properly
assessed before crane
operations can begin; heavy
goods vehicle drivers‟ license.
Forklift Operator
Forklift Operations
CITB / RTITB or equivalent
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Procedure for Lifting Operations
Page 17 of 55
Level 2 / 3 EAL / ECITB /
Site “Competent Person”
All Categories
CITB or equivalent
LEEA / NSL Module 1 or hold
current formal qualifications
Lifting Inspector
Equipment Inspection
with three years lifting
experience
Level 2 / 3 EAL / ECITB /
Site Lifting Coordinator
All Categories
CITB or equivalent
Relevant level of engineering
and leadership experience as
Lifting Technical Authority
Complicated / Complex
endorsed by AzSPU
Engineering Authority
8
ROLES and RESPONSIBILITIES
Every lifting operation must be:
¾ Properly planned by a competent person
¾ Appropriately supervised
¾ Carried out in a safe manner
Lifting activities usually involve several craft disciplines and authorities.
It is therefore important that any system set up to manage lifting operations safely, must
recognize this inherent complexity and must ensure that roles and responsibilities and the
competencies for each activity are clearly defined, recognized and that there is a shared
view of interfaces and boundaries. This section details the roles and responsibilities of these
stakeholders.
Given the differences in job titles for similar roles across the operations, contract strategies
etc., the roles listed below are generic. However, each site and installation must translate
and appoint the responsibility to suit its own organization.
Lifting operations roles may be combined, e.g. deck foreman and lifting supervisor but it is
essential that these roles are clearly stated at each site and understood by all.
The generic stakeholders are:
¾ Site Manager / Site Coordinator / Offshore Installation Manager
¾ Area Authority
¾ Banksman
¾ Rigger / Slinger/ Load Handler
¾ Crane Operator
¾ Forklift Driver
¾ Site Competent Person
¾ Lifting Inspector
¾ Site Lifting Coordinator
¾ Lifting Technical Authority
¾ Senior Technical Authority
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Procedure for Lifting Operations
Page 18 of 55
8.1
Site Manager / Site Controller / Offshore Installation Manager:
The Site Manager / Site Controller / Offshore Installation Manager shall be responsible and
accountable for the application of this procedure in his area of responsibility, He shall
ensure:
¾ Adequate numbers of Competent responsible persons are appointed to manage and
maintain the requirements of this procedure
¾ This procedure is strictly adhered to for all occasions when it is identified that lifting
operations are to take place
¾ Formal records of all risk assessments are maintained in accordance with this
procedure
¾ A competent person is appointed to inspect and certify lifting equipment is safe to use
¾ No lifting equipment is allowed or used on site unless it is accompanied by all relevant
certification and in date test certificates
¾ Adequate records are maintained for all lifting equipment, including certification,
examination and test reports
¾ Competent Persons are appointed to compile lifting plans and to perform lifts
¾ Competent Persons are appointed to control the issue and inspection of lifting
equipment
¾ All lifting operations are planned and that, where necessary, plans are recorded
8.2
Area Authority:
The Area Authority shall be responsible for ensuring that the requirements of this procedure
are adhered to for all lifting operations within his area of responsibility. He shall ensure:
¾ The lifting operation has been risk assessed and planned
¾ All persons involved in lifting operations are instructed on the requirements of risk
assessment, permit to work conditions, and any risks or hazards associated with the
work activity
¾ Regular inspection is performed on all lifting activities to confirm that conditions are
suitable and sufficient and, that all personnel are in compliance with this procedure
¾ The Lifting Supervisor conducts risk Assessments, Toolbox Talks, and Task Risk
Assessments
8.3
Banksman:
A Banksman shall be properly trained, proven to be competent, and is authorized to perform
his duties.
The Banksman‟s duties are to communicate clear and precise commands to the crane
operator.
Depending on the complexity and importance of the load and lifting operation, the person in
charge will supervise and act as Banksman for all movements and precision positioning lifts.
The Banksman shall accompany and guide the crane assigned to them during all its
movements on site.
Lifts are to be carried out only in the Banksman‟s presence and he is the ONLY authorized
person to give instructions to the crane driver and the crew during lifting operations.
Control Tier:
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Procedure for Lifting Operations
Page 19 of 55
The Banksman must meet the following requirements:
¾ Should never be involved in lifting operation itself
¾ Not touch the load and back from the load in a prominent position with a good view of
the lifting activities and any obstructions
¾ Remain in communication with the slinger / load handler and crane operator at all
times
¾ Keep the load handler in sight during the lifting operation
¾ Be capable of understanding slinging / lifting arrangements suitable for the load.
Understand fully the hand signal codes and be able to give clear and precise signals
and / or instructions
¾ Be capable of directing the movements of the crane and load in such a manner as to
ensure the safety of personnel and plant equipment
¾ Be known and clearly identifiable to all concerned by wearing high visibility
identification
8.4
Slinger / Load Handler:
The Slinger / Load Handler shall prepare the load for lifting according to the lifting plan and:
¾ Stand clear while lifting or landing a load on the deck, while slack is taken up with or
without a load on the hook, and must confirm to the banksman that he is clear
¾ Prepare load to be lifted using suitable lifting equipment, chain blocks, slings, etc
¾ Not touch a load until it is landed, or until it is below waist height, and never attempt to
manually stop a swinging load
¾ Be easily identifiable, and distinct from the banksman
8.5
Crane Operator:
A crane operator shall be properly trained, authorized, competent, and fully conversant with
all aspects of safe crane operation. In particular, they must be familiar with the controls and
capabilities of the crane that they are to drive and operate.
The crane operator is responsible for ensuring that all servicing routines have been carried
prior to crane operation to ensure that the crane can function correctly and is available to
carry out the necessary lifting operations as required.
The crane operator must read and understand lifting plans and confirm crane capability with
regard to load and boom angles.
Offshore crane operators shall be qualified to the OPITO (Sparrows) stage 3 or equivalent.
Mobile crane operators shall have the correct operators licence for the crane type they are
operating.
The crane operator has ultimate responsibility for loads being lifted or moved by the crane.
The crane operator should satisfy themselves that the operation in hand has been risk
assessed and included in the toolbox talk and that the appropriate Permit to Work and lifting
plans are in place.
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Procedure for Lifting Operations
Page 20 of 55
8.6
Forklift Driver:
A forklift driver shall be properly trained, authorized, competent, and fully conversant with all
aspects of the machine safe operation.
No untrained person shall operate a forklift.
8.7
Site Competent Person:
It is mandatory for all BP controlled sites that carryout lifting operations to have a suitably
qualified Site Competent Person onsite.
The Site Competent Person (e.g. deck foreman, site lifting and rigging supervisor) must have
adequate technical and practical knowledge and experience to visually inspect lifting
equipment to confirm continued fitness to use, answer queries about the suitability of lifting
equipment, to advise, develop and execute lifting plans.
The Site Competent Person will:
¾ Manage and control the rigging and lifting loft inventory
¾ Maintain the register of generic and specific site lifting plans and risk assessments
¾ Maintain the register of persons authorized to perform lifting operations
¾ Assist the Lifting Coordinator with the development of lifting plans
¾ Develop lifting plans and risk assessments for all lifts
¾ Continuously review the generic lifting assessments for routine lifts
¾ Act as the Performing Authority (under PTW if appropriate) for all lifting operations
¾ Have the responsibility for all site lifting activities deck and
/ or boat handling
operations
8.8
Lifting Inspector:
The Lifting Inspector shall:
¾ Develop a thorough examination program for fixed lifting equipment
(excluding
offshore pedestal cranes)
¾ Carry out a thorough examination of fixed lifting equipment and ad hoc inspection of
any other relevant types of lifting equipment
¾ Be responsible for ensuring colour coding and certification of examined equipment
¾ Ensure that all lifting equipment on site has test and examination certificates
¾ Ensure that all lifting equipment on site and in use is within current test dates
¾ Ensure that all lifting equipment on site and in use is colour coded to indicate current
usage dates
¾ Ensure that all lifting equipment on site and not in use is stored according to
manufacturers instructions
¾ Ensure that all lifting equipment on site is inspected either prior to issue or on return
from use
8.9
Site Lifting Coordinator:
Primary role of the Site Lifting Coordinator is to provide continuous review of lifting practices
to ensure compliance with this SSOW.
Control Tier:
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Procedure for Lifting Operations
Page 21 of 55
The Site Lifting Coordinator has a coordination role, and is responsible for ensuring that a
regime is established and maintained on the site such that lifting operations are carried out
safely. This will require:
¾ The authorization of all lifting plans and risk assessments for all categories of lifts by
the nominated Lifting Coordinator supported by the Lifting Authority and Mechanical
Handling Contractor‟s (MHC) support engineer as appropriate. This includes ensuring
that it is clear who is in charge of specific lifting operation.
¾ Ensuring that all personnel involved with any lifting operations on the site have proper
training and are assessed as competent to SSOW standards and that a register and
documentation of such personnel is maintained on the installation / site. This includes
resident site personnel and any ad hoc personnel. The person must also have an in
depth knowledge of the relevant legislation, regulations, standards, company
procedures, health and safety aspects, and industry best practice
8.10 Mechanical Handling Contractor‟s (MHC) Technical Support Engineer:
The MHC Technical Support Engineer is nominated as the person responsible for providing
technical expertise in support of complicated lifts (where applicable) and ALL complex lifting
operations on the installation / site. This includes the endorsement of the scope of method
statements, lifting plans and task based risk assessments, discussion with specialist
engineers and contractors. Ensuring all relevant engineering standards are applied during
the development phase of the work scope and that the output from the engineering studies /
assessments are documented and recorded.
8.11 Lifting Technical Authority (LTA):
The Lifting Technical Authority is responsible for providing the technical overview for lifting
operations on sites.
The LTA is responsible for ensuring complicated lifts (where applicable) and ALL complex
lifts are engineered to the relevant standards.
The LTA is the Technical Authority for this SSOW.
8.12 Senior Technical Authority (STA):
Has overall technical responsibility for all Lifting and Rigging operations. The STA is
responsible for nominating and ensuring competency of LTA.
9
COMMUNICATIONS
A uniform communication system clearly understood by all site personnel taking part in lifting
operations including radio sets and hand signals, shall be established and used in the
process of all lifting operations.
The communications that are required for lifting operations shall be specified in the lifting
plans.
Control Tier:
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Document Number: << AZSPU-HSSE-DOC-00056-2>>
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Procedure for Lifting Operations
Page 22 of 55
Note: In noisy areas, headsets for radios will be required. If radios are to be used, crane
operators shall have hands free sets.
Charts with standard hand signals for controlling lifting operations explaining the system of
signals used shall be conspicuously posted in the vicinity of the areas dedicated
permanently for lifting operations.
10
RISK ASSESSMENT AND PLANNING OF LIFTING OPERATIONS
10.1 Strategy
Risk Assessment
All lifting operations must undergo a risk assessment in accordance with Safe Systems of
Work procedure. Simple and Routine operations require a Level 1 risk assessment and
Complicated and Complex require a Level 2 risk assessment. Guidance for lifting operations
risk assessment is included in this document in Section 10.3.
Generic lifting operations shall be reviewed on a regular basis to ensure that the original
risk assessments remain valid.
For all lifting operations, the degree of risk identified during the risk assessment shall
determine the level of supervision required for the operation and the required experience of
the personnel involved. In particular, the risk assessment should account for:
¾ Working under suspended loads
¾ Attaching and detaching the load
¾ Overloading
¾ Overturning
¾ Breakdown in communication during lifting (especially blind lifting)
¾ The environment and location
¾ Proximity hazards
¾ Pre-use checks by the operator
¾ Deterioration in the condition of lifting accessories
¾ The experience, competence, and training of available personnel
Risk Assessment shall specifically consider manning requirements for safe conduct of
complex and blind lifts to ensure clear communication between all team members
participating in the lifting operation.
Planning
Following a risk assessment, and the preparation of a standard instruction or procedure, the
person using the equipment can normally plan routine lifts on an individual basis. In any
event, the person planning the operation shall have adequate practical and theoretical
knowledge and experience of planning lifting operations.
The degree of planning will vary depending upon the:
¾ Type of lifting equipment
¾ Complexity of the lifting operation
¾ Degree of risk involved.
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Procedure for Lifting Operations
Page 23 of 55
As a minimum, the plan shall address the risks identified and should identify all resources,
procedures and responsibilities necessary to ensure a safe operation.
All lifting operations shall be:
¾ Properly planned by a competent person
¾ Appropriately supervised
¾ Carried out in a safe manner
In addition to the above requirement, the AZSPU-HSSE-DOC-00063-2 Task Risk
Assessment SSOW imposes a duty to carry out a suitable and sufficient risk assessment to
identify the nature and level of hazards associated with work.
No lifting and rigging operations should be carried out without a lifting plan produced by a
competent person and approved by relevant authority, unless an approved site specific
procedure is in place and approved by the relevant Lifting Technical Authority.
To remain cognisant of this SSOW, it is recommended that the asset management compile a
series of generic lifting plans to cover routine lifting duties.
A number of Integra generic lifting plans and risk assessments for general lifting operations
on and offshore have been prepared. This format is approved for generic routine lifting
operations only and planning for non routine lifting operations shall be carried out on the
format demonstrated in this document. Refer to Integra generic lift plans and risk
assessments in Appendix
10.2 Spheres of Responsibility
The spheres of responsibility and interfaces for lifting operations are as shown below.
Site Authority
&
Supervision
Operation:
Planning:
Crane Operator
Competent Person
Risk
Rigger
Discipline Engineer
Assessment
Slinger / Banksman
Rigger
Basic Slinger
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Procedure for Lifting Operations
Page 24 of 55
10.3 Planning Process
Lift categories
To assist with the risk assessment process, lifting operations are divided in four categories,
which are:
¾ Routine
¾ Simple
¾ Complicated
¾ Complex
Routine and simple lift:
This category of lifting operation is implemented using generic lifting plans and risk
assessments, each with clearly established criteria and limitations. Competent lifting
personnel then review the generic plan at a toolbox talk prior to implementation.
Complicated lift:
This category of lifting operation requires a written method statement in addition to the lifting
plan, risk assessment, and the approval of Site Lifting Coordinator and / or Mechanical
Handling Contract Technical Support or the Lifting Technical Authority. Competent lifting
personnel then review the specific plan at a toolbox talk prior to implementation.
Complex lift:
If a lifting job involves divers or subsea work or the plan indicates the selected route for the
load to travel is over live plant or a confined space, it is classed as a complex lift. This
category of lifting equipment requires a written method statement in addition to the Lifting
plan, risk assessment, and the approval of Site Lifting Coordinator and/or the Mechanical
Handling Contract Technical Support or the Lifting Technical Authority.
Minimum number of people required to carryout the complex or complicated lifts
safely shall be risk assessed and established prior to start the lifting operation.
Note: Where the lifting activities - routine, simple, complicated, or complex - are likely to be
repeated, the assessments, lifting plans and method statements should be held on file for
subsequent review and reuse.
Routine activities by definition are repetitive and as such, the method statements, risk
assessments, plans, and any supporting procedures should be held on file.
Control Tier:
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Procedure for Lifting Operations
Page 25 of 55
Lifting Plan Decision Tree
Lifting Operation Required
Review Library of
Approved Lifting plans
Has the lift been carried
Yes
and Risk Assessments
out before?
No
Categorise Lifting Operations (review all
Is plan and risk
No
lifting categories to determine the
assessment still
appropriate category)
applicable?
Yes
Proceed with Lift
Is it a Routine Lift?
Is it a Simple Lift?
Is it a Complicated Lift?
Is it a Complex Lift?
(Use lifting category
(Use lifting category
(Use lifting category
(Use lifting category
assessment)
assessment)
assessment)
assessment)
Plan & Risk Assessment
Plan & Risk Assessment
Plan & Risk Assessment &
Plan & Risk Assess. &
approved by Nominated
approved by Nominated
Method Statement
Method Statement
Competent Person
Competent Person
approved by Nominated
approved by Nominated
Competent Person
Competent Person
Lifting Co-ordinator
Lifting Co-ordinator
Authorisation/Decision
Authorisation
If required
Plan & Risk Assessment endorsed
by LTA, MHC Engineer
Lifting
LTA / MHC
Lifting Coordinator
Lifting Coordinator
Coordinator
Authorisation
Authorisation (including
Authorisation (including
Authorisation
Generic lifting plans)
Generic lifting plans)
Proceed with Lift
Hold toolbox talk &
Hold toolbox talk &
Hold toolbox talk & proceed
Hold toolbox talk &
proceed with the
proceed with the Lifting
with the Lifting Operation
proceed with the Lifting
Lifting Operation
Operation following the
following the specified Lifting
Operation following the
following the
specified Lifting plan
plan and site controls
specified Lifting plan and
specified Lifting plan
and site controls
site controls
and site controls
Lift Supervised by
Lift Supervised by
Lift Supervised by
Lift Supervised by
Rigger with
Rigger/Technician
Rigger/Technician
Rigger/Technician
Competency
with Competency
with Competency
with Competency
Level 1 (min)
Level 1 (min)
Level 3 (min)
Level 3 (min)
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Procedure for Lifting Operations
Page 26 of 55
Wind Speed Limitations
No cranes shall be operated outside of manufacturers recommendations
It is responsibility of the Site Lifting Coordinator to utilize accurate and realistic wind speed
readings using an anemometer set in an appropriate location.
Suspend lifting operations when average wind speeds reach:
¾ Onshore - 25 knots (12.86 m/sec)
¾ Offshore - 35-40 knots (18 - 20.5 m/sec)
Lifting operations may be allowed to restart following:
¾ A formal task specific risk assessment involving Site Manager, Site Lifting Coordinator
and HSE Advisor taking into consideration site conditions, industry guidelines, crane
manufacturers recommendations, type / weight / shape / of load being lifted
¾ Upgrading the lift category to „complicated‟.
¾ Continuous monitoring of the weather / site conditions including wind gust speeds.
It is the accountability of the Site Manager / Site Controller / Offshore Installation Manager to
ensure that when lifting operations are restarted the above items shall be considered and the
appropriate limits are agreed, understood, and recorded.
Risk Assessment - guidance notes:
This section is for guidance purposes only. Whilst it tries to incorporate the main hazards
associated with lifting operations, these notes are not intended to be exhaustive. Other
equally significant hazards may be present.
Where other hazards are identified, these shall be assessed in a similar fashion to those
identified on the notes, with due consideration to possible causes, consequences and
appropriate solutions.
Planning for the worst case scenario should ensure that all hazards have been brought to
ALARP Level and the necessary mitigation actions are in place.
Important:
Lifting more than one dedicated load at a single time is strictly prohibited and should not be
carried out under any circumstances.
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Procedure for Lifting Operations
Page 27 of 55
RISK ASSESSMENT GUIDANCE NOTES
1) The load
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Incorrect weight on
Equipment failure
Trial lift
manifest
Load falling
Dynamometer
Load heavier
Weight unknown /
Equipment instability /
Ensure personnel
than expected
incorrect estimate
collapse
emergency access
Lifting equipment
Personnel injury
route
overloaded
Reposition lifting
equipment
Incorrect information
Load swinging
Centre of
Trial lift
supplied
Load striking person
gravity not as
Ensure personnel
Incorrect slinging
Load striking plant
expected
emergency access
Cargo shifting in transit
Personnel injury
route
Fit tag lines
Consider alternative
slinging method.
Use specialised
Insufficient head room
Load striking plant
Physical
lifting equipment e.g.
Nearby plant and
Load handling problems
dimensions
low headroom hoist
machinery
Personnel injury
Use of additional
banksman / radios
Fit tag lines
Consider alternative
slinging method.
Falling objects
Load
Transit damage
Pre-lift check
Load falling.
damaged
Sharp corners
Ensure emergency
Personnel injury
access route.
Correct PPE.
2) The environment
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Excessive wind speeds.
Load swinging.
Poor visibility - light, mist
Load striking person
Fit tag lines
or fog
Adverse
Load striking plant
Use of additional
High sea states
weather
Personnel injury
Banksman / radios
Rain, sleet or snow
conditions
Snatch load
Correct PPE.
showers,
Crane overload
Do not carry out lift
Ice on load and deck /
Slips trips and falls
ground
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Procedure for Lifting Operations
Page 28 of 55
3) Controlling the area
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Barrier off area.
Unaware of lifting
Load striking person
Use of additional
operation
Pedestrians
Personnel injury
Banksman assistance /
Ignore barriers
radios.
Unaware of risks
Keep people away.
Lifting over the heads of
Persons involved in lifting
Consult Permit issuing
Other work
persons involved in other
operation not aware of
Authority.
activities in the
work front in the vicinity.
other nearby work
Check area prior to
vicinity
Load striking person.
activities
operation
Personnel injury
Use suitably trained
Load swinging
Untrained personnel
personnel
Breakdown in
Load striking person
Radio problems
Use of additional
communications
Load striking plant
Blind lifts.
banksman assistance /
Personnel injury
radios
4) The lifting equipment
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Incorrect selection of
Double check SWL
equipment
required prior to lifting.
Equipment failure
Incorrect assessment of
Use dynamometer
Incorrect SWL
Load falling.
weight of load
Remember to include
Personnel injury
Incorrect calculations of
weight of accessories
forces
for lifting
Incorrect selection of
equipment
Lifting
Human error
Pre-use check
accessories not
Load falling.
Shackles of containers
Ensure tie-rap/safety
attached
Personnel injury
unscrewed in transit
pin fitted to shackles.
correctly
Safety latch of hooks
damaged
Pre-use check
Lack of maintenance
Equipment failure
Review and correct
Mechanical
Incorrect use of equipment
Load falling
maintenance plan.
damage
Contact with sharp edges
Personnel injury
Review and correct
General wear and tear
storage method
Load swinging.
Re-position lifting
Incorrect fleet
Lifting appliance not
Load striking person.
appliance prior to
angle
positioned directly over load
Load striking plant.
operation
Personnel injury
Pre-use check
Equipment out
Equipment failure
No pre-use check
Correct colour code.
of date
Violation of procedure
Check certification.
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Procedure for Lifting Operations
Page 29 of 55
5) Personnel
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Incorrect choice of
equipment
Incorrect attachment of
Ensure adequate
lifting accessories
training
Human factors
Incorrect operation of
Check competency
Inadequate
Inadequate training
equipment
level of personnel
knowledge
Lack of competence
Load swinging
involved in lifting
base
Load striking person
operation.
Load striking plant
Increase supervision
Equipment damage
Personnel injury
Incorrect choice of
equipment
Incorrect attachment of
lifting accessories
Pre-job safety
Slips
Incorrect operation of
meetings
Human factors /
Lapse
equipment
Realistic time frame to
Errors
Mistakes
Load swinging
perform job
Load striking person
Increase supervision
Load striking plant
Equipment damage
Personnel injury.
6) Structural
HAZARD
POSSIBLE CAUSE
CONSEQUENCE
SOLUTION
Engineering
calculations
Proof load testing
Dropped object
Incorrect load applied to
Equipment fitted or
Load striking person
Structural
structural component
fitted by
Load striking plant
collapse
Lifting equipment not fitted
trained/competent
Personnel injury
and assembled correctly
personnel
Thorough examination
by competent person
prior to use
Engineering
Mobile crane instability
calculations
Deck failure
Deck collapse
Inadequate surface loading
Correct anchorage
Dropped object
Ground
Capacity for weight of load
Spreader plates placed
Load striking person
subsidence
Environmental conditions
under load or mobile
Load striking plant
crane outriggers
Personnel injury
Soil testing
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Procedure for Lifting Operations
Page 30 of 55
7) Principles of a safe lift
Before the lift:
1. Ensure personnel are competent.
2. Assess the load and identify the risks.
3. Select the correct lifting equipment.
4. Carry out a pre-use check.
5. Ensure lifting equipment is fitted correctly.
6. Identify what could go wrong and take appropriate precautions.
7. Control the danger zone during lifting operation.
8. Prevent the load from swinging.
9. Avoid trapping hazards and lifting over personnel.
10. Ensure there is adequate space to land the load.
After Lift:
1. Check equipment after use.
2. Store in correct conditions.
All Lifting Operations must have appropriate Lifting Plan in place.
Questions
Yes
No
1
Has this lifting operation been performed before?
2
Is an approved procedure available?
3
Is the lifting team experienced with all the lifting equipment used?
Has the load been checked and made ready for lifting (e.g. sea
4
fastenings released, hold down bolts removed)?
Does the lifting team have the experience to lift a load of this
5
weight or size?
Is the lifting area free from obstructions and other possible
6
hazards?
Can the lifting operation be carried out without the use of webbing
7
slings? Is a site specific procedure for the use of webbing slings
available?
If the answer to any of the above is “No”, go to Part 2 (Simple Lift)
Important: If you find a problem, stop the job and ask!
Routine lifts (Part 1)
If the answer to all questions above is “Yes”, proceed with the Routine lift.
Assessment of Part 1 performed by ________________________________
Job title __________________________
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Procedure for Lifting Operations
Page 31 of 55
Date ____________________________
For Standard Form go to: Baku office on Eubaks5/Operations/Safety &
Environment/Checklist
Simple lifts (Part 2)
Questions
Yes
No
Do you know the weight of the load and does the lifting operation
1
appear to be straightforward?
If the load is heavier than you normally handle, do you have the
2
relevant permission and / or permit?
Is there a crane or certified support steelwork (e.g. runway beam or
3
lifting eye) directly above the load?
Does the load have certified lifting points (lifting eyes / collar eyebolts,
4
etc) fitted and if not, can slings be wrapped around easily (e.g. no sharp
edges, load not fragile, etc)?
5
Is there ample headroom for the lifting appliance and slings?
6
Is the lift stable (e.g. centre of gravity below lifting points)?
Is the lift balanced (e.g. centre gravity in the middle) or fitted with
7
special slings to compensate?
Is the load free to be lifted (e.g. sea fastenings released, all hold-down
8
bolts removed, not jammed, etc.)?
9
Is the removal route clear of any obstructions?
Can the removal (lift, transfer, and landing) be performed without cross
10
hauling?
Is there suitable lay down area and does the load come within the
11
allowable load bearing capacity of the ground/deck?
Are you experienced in using all the lifting equipment and gear
12
involved?
Can the lifting operation be carried out without the use of Webbing
13
Slings? Or is a site specific procedure for the use of webbing slings in
place?
If the answer to any of the above is „No‟ go to Part 3 (Complicated Lifts)
If the answer to all questions above is “Yes” proceed with the Simple lift.
Assessment of Part 2 performed by _____________________________________________
Job Title ___________________________________________________________________
Date ______________________________________________________________________
NOTE: To the Site Competent Person:
If you can give solutions to the negatives in the above questionnaire to allow the lift to
proceed safely, write the instructions in the box. If you cannot supply a solution, seek
guidance from the Lifting Coordinator.
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Procedure for Lifting Operations
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For Standard Form go to: Baku office on Eubaks5/Operations/Safety &
Environment/Checklist
Complicated Lifts (Part 3)
The personnel about to perform the lifting operation shall complete the table below.
Tick against factors, which are applicable and specific to this lifting operation and indicate
whether or not you have the relevant experience to deal with them.
QUESTIONS
Yes
No
Is the lift stable? (i.e. centre of gravity below the lifting points and
1
not offset) .
Is the centre of the gravity for the load viewed as balanced and
2
acceptable?
Can the lift be performed without cross-hauling or being
3
restrained by using one or more mechanically driven devices?
4
Does the load have specific lifting attachments?
5
Is the load robust? (not fragile)
Does the load have a limited surface area that will not cause
6
instability in the wind?
7
Does the load require only one crane? E.g: no tandem lifting
8
Can the lift be performed without rotation?
Uncertified structural components- can the lift be carried out
9
safely without the need for MHC engineering calculations
If the answer to any of the above is “No” go to Part 4 (Complex Lifts)
If the answer to all questions above is “Yes” proceed with the Complicated Lifts. See Note for
guidance No Answers
Assessment of Part 3 performed by________________________________________
Job title ______________________________________________________________
Date ________________________________________________________________
Approved/Endorsed by_________________________________________________
Job Title ____________________________________________________________
Date __________________________________________________________________
NOTE : To the Lifting Coordinator:
If you have experience and can advise personnel involved in the lifting operation how to deal
with the complication, allow the task to proceed but only under your guidance. However if
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Procedure for Lifting Operations
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you decide that the operation is out with the scope of your competence, indicate the reasons
applicable in the table in Part 4 complex lifts before passing it to the LTA
For Standard Form go to: Baku office on Eubaks5/Operations/Safety &
Environment/Checklist
Complex Lifts (Part 4)
Lifting operations or conditions, which would merit additional engineering input
Tick
REASONS FOR REQUESTING ENGINEERING INPUT
box
1
The lifting operation involves divers
2
The lifting operation is sub-sea
3
The load will be travelled over unprotected process plant and machinery
The load is classified as heavy (>80% of crane rated capacity) and is not
4
being transported in CCU
5
The lift involves a floating crane
6
The load is critical to business
The lift is in a confined space and/or an area with very restricted
7
headroom.
Use of non-certified structural components, which require engineering
8
calculation
Personnel Transfer / Man-riding activity where no approved site specific
9
procedures exist
Lifting Plan / Method Statement and Risk Assessment Part 4 performed by
______________________________________________________________
Job Title________________________________________________________
Date __________________________________________________________
Approved / Endorsed by (delete as applicable)
For Standard Form go to: Baku office on Eubaks5/Operations/Safety &
Environment/Checklist
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Procedure for Lifting Operations
Page 34 of 55
Appendix A
Glossary of Terms
Anomaly:
A condition which falls outside the present design criteria for the equipment.
Asset
Offshore complex, sub-sea facility, transportation line an onshore terminal and loading
facilities.
Azerbaijan Strategic Performance Unit:
All operations conducted by or on behalf of any Performance Unit or Project in Azerbaijan,
Georgia, or Turkey.
Lifting Equipment Engineering Association (LEEA):
An independent organisation recognised as the technical authority within the industry
responsible for establishing Codes of Practice and training standards.
Non-Statutory examination:
Examination carried out by a person deemed to be competent to determine whether or not a
lifting equipment item is safe to use.
Thorough Examination:
Statutory examination carried out by a competent person for the purpose of certifying that an
item of lifting equipment is free from patent defect and is satisfactory for further use as
specified by the manufacturer.
Heavy Lift:
When a load is equal to or greater than 80% of the rated capacity of the crane, the lift shall
be classified as a heavy lift.
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Procedure for Lifting Operations
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Appendix B
Inspection & Certification of Temporary or New Cranes
Temporary or new cranes on site must have relevant certification and be inspected before
use by a competent person. The certification and inspection should in include as a minimum
the items on this spread sheet.
Crane Certification Details
Make:
Tag / ID No:
Inspection Date :
Serial No:
SWL :
Test Cert No:
Previous Inspection Details
Date of Test:
Company:
Inspector :
Date of Last Visual:
Company:
Inspector :
Visual Cert No:
Company:
Inspector :
Crane Equipment
Main Hoist Rope
Serial No:
Cert No:
Date Fitted:
Boom Hoist Rope (Luff) if fitted
Serial No:
Cert No:
Date Fitted:
Whip Line (If fitted)
Serial No:
Cert No:
Date Fitted:
Headache Ball (If fitted)
Serial No:
Cert No:
Date Tested:
Crane Block
Serial No:
Cert No:
Date Tested:
Boom Pennant Lines (If fitted)
Serial No:
Cert No:
Date Fitted:
Wedge Sockets (If fitted)
Serial No:
Cert No:
Date Fitted:
Load Indicator and load chart
SLI Type:
Model:
Calibration Date:
Load Chart visible Yes /
Boom Angle indicator: Yes /
Load Chart: Yes / No
No
No
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Procedure for Lifting Operations
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Appendix C
References
1. Use of Equipment Directive (95/63/EC)
2. Health and Safety at Work Act 1974
3. Management of Health Safety at Work regulations 1999 (MHSAWR) SI 1999/3242
4. Provision and Use of Work Equipment Regulations 1992 S.I.2306 (PUWER)
5. The Supply of Machinery (Safety) Regulations 1992 S.I.3073
6. Manual Handling Operations Regulations 1992
7. HSE 3268 Lifting Operations & Lifting Equipment Technical Guidance (Relevant to
offshore lifting & handling appliances)
8. NSL: International Rigging and Lifting hand book 2001 Rev2.
9. UKCS-TI- 014.
10. BP North Sea Lifting Rules.
11. BS 7121 “Safe use of Cranes”
12. EN 12079 CCUs
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Procedure for Lifting Operations
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Appendix D
Generic Lifting Plans - Simple
Offshore
Lift plans for platforms - Integra 001 LP and RA Designated landing areas
Lift plans for platforms - Integra 002 LP and RA Bulk hose supply vessel
Lift plans for platforms - Integra 003 LP and RA scaffold tubulars
Lift plans for platforms - Integra 004 LP and RA back load offload supply vessel
Lift plans for platforms - Integra 005 LP and RA wooden crates
Lift plans for platforms - Integra 006 LP and RA Rig skidding
Lift plans for platforms - Integra 007 LP and RA preslung cargo
Lift plans for platforms - Integra 008 LP and RA long awkward loads supply vessel
Lift plans for platforms - Integra 009 LP and RA Close to turbine exhausts
Lift plans for platforms - Integra 010 LP and RA slew limit overide
Lift plans for platforms - Integra 011 LP and RA to and from baskets-containers
ASCO Base / Quay side
ASCO lift plans for the lifting SSoW - Integra 001 LP AND RA base-yard-quayside CCU
ASCO lift plans for the lifting SSoW - Integra 002 LP and RA base-yard-quayside Tubulars-pre-slung
materials
ASCO lift plans for the lifting SSoW - Integra 003 LP and RA Supply vessel operations CCU
ASCO lift plans for the lifting SSoW - Integra 004 LP and RA Supply vessel long akward loads
ASCO lift plans for the lifting SSoW - Integra 005 LP and RA Supply vessel bulk hose handling
ASCO lift plans for the lifting SSoW - Integra 006 LP & RA Supply vessel Attaching and removal of
gangways
ASCO lift plans for the lifting SSoW - Integra 007 LP and RA Supply vessel operations LDCB empty
ASCO lift plans for the lifting SSoW - Integra 008 LP and RA Supply vessel LHM 250 Crane
operations LDCB full
ASCO lift plans for the lifting SSoW - Integra 009 LP and RA Excavator, Supply vessel Attaching and
removal of gangways
ASCO lift plans for the lifting SSoW - Integra 010 LP and RA Excavator, base-yard-quayside
Tubulars-pre-slung materials
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Procedure for Lifting Operations
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Examples of Lifting Plans - Complicated
Title
Area
Remove Runway Beam
AIOC Chirag 1M2A CD
Lifting Plan No.
CH-P-LP-002
Generic / Specific: Specific
Risk Assessment No.
Category Of Lift Complicated
Date
Revision Rev 1
Rev 1
Diagrams, Drawings or Sketches attached.
Max Weight of Load :
1.4te Actual.
Actual / Assumed / Calculated
Brief Description of Lifting Operation / Sketch:
Remove the maintenance runway beam.
Certified Lifting Equipment and Accessories to be Used (Specify Type, SWL and Colour Code):
4 x 2te swl chain-blocks, 8 x 3 et swl wire slings, 6 x 4.75 te swl bow shackles,1 x 3te pull-lift. Colour code green.
Cross Reference Relevant Procedures and Documents: i.e. DOG, engineering Calcs etc
Ref; EQ KA00-EQ104.
All Lifting Operations Require The Following To Be Considered But This List Is Not Exhaustive
Every Lift Every Time
Specify, Yes / No
Pre-use equipment checks by competent person.
Working under suspended loads.
Yes/No
All lifting equipment should have SWL identified.
Route adjacent to or over live plant:
Yes/No
Weight, size, shape, certification and centre of
Conflicting tasks in area/adjacent worksites.
Yes/No
gravity.
Trial lift required.
Yes/No
Risk of overturning, Cross hauling, tandem lift: Yes/No
Proximity hazards, obstructions, path of load,
laydown area load bearing capacity
Method of slinging/attaching/detaching the load. Yes/No
Availability of certified lifting points.
Yes/No
Environmental conditions including weather / Sea.
Lift is in Crane Radius.
Yes/No
Responsibilities clearly defined eg rigger / slinger /
Safe access / Scaffolding.
Yes/No
banksman.
TRA level 1/2 - agree with AA
Experience, competence and training of personnel.
Confirm No of Tag Lines Required:
1
All lifts must be checked for loose objects.
Confirm Number of personnel required for task:
4
PTW to be raised / TRA level 1
Task Details (step by step)
Safety.
All rigging equipment being used for this task will have a minimum SWL of 2Te.
A minimum of 2 pieces of rigging equipment will support the beam at all times.
Barriers must be erected to ensure nobody can walk under this load.
A tannoy announcement will be made to stay clear of the area.
Isolate the line of sight gas detectors. Ash 016.
Care must be taken whilst rigging close to Ash 016, hold back rigging must be in place to ensure
the beam does not touch the monitor.
Pre-rigging
Safely secure a 3 Te Swl sling 2.5mtrs from the North end of the runway beam.
Safely secure 2 x 3 Te Swl sling 2.5mtrs from the South end of the runway beam.
Safely secure 4 x 3Te chain blocks to the sub main deck 300mm x 152mm “I” beams.
Safely secure 4 x 2te minimum swl wire slings directly under the chain-block locations , secure the chain blocks to
the slings, take weight.
Methods of communication to be used :
Radio
/
verbal
/
hand signals
Steps to be taken to eliminate danger to personnel: barriers / permit to work procedure / tannoy / toolbox talks /
lifting plan / no conflicting tasks in the area.
(delete as appropriate)
Authorisation:
Level of Operational Control: Area Authority / Permit to Work
Engineering Support Required: No
Competent Person
Signature
Date
Reviewed by
Signature
Date
De-brief and Learning Points
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Procedure for Lifting Operations
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Examples of Lifting Plans - Complex
Title
Area
Lifting plan for the purpose of lifting drilling template
Azfen fabrication yard quayside (Baku)
and associated floatation
Lifting Plan No.
CH-P-LP-002
Specific:
Specific
Risk Assessment no.
Category Of Lift
Complex
Date
Revision Rev 1
Rev 1
Diagrams, Drawings or Sketches
Max Weight of Load :
Actual / Assumed /
Cradle- (Design)
attached.
Calculated.
50500kg
Task Details (step by step)
Lift template onto the cradle using Titan crane barge (interface test as detailed in FAT E687)
Attach 4 25 tonne safety bow shackles to the lifting points/pad eyes (identified on drawing 3847/01).
Whilst at ground level, attach 4 off single leg “jumper” slings (Single leg wire rope sling “ 3,5Mx38mm dia,
6x36 IWRC RHOL Galv C/W soft eye each end, 18.6 tonne SWL template lift sling via 4 off 25 tonne
shackles.
Crane hook to swivel sling (2 leg wire rope Assy 3 metre x 64 mm dia, 6x36IWRC galv RHOL fitted to HA 70
ML masterlink C/W hard eyes all round.
Attach a 55 tonne safety bow shackle to the aforementioned sling master-link.
Fit 55 tonne swivel to the aforementioned 55 tonne safety bow shackle keeping any manual handling
(lifting/bending) to an absolute minimum.
Attach the other 55 tonne safety bow shackle to the bottom of the 60 tonne swivel.
Attach the (2 off-2 leg wire rope sling assy 4.1Mx38mm dia 6Xiwrc GALV RHOL fitted to HA 45 ML
masterlink C/W hard eyes) and 4 off single leg template lifting sling assembly to the 55 tonne shackle via the
master link.
Attach tag lines to the end of the lift assembly.
Under the supervision of the lift supervisor, slowly lift and position each individual sling assembly leg such as
it can be assembled to the template via the 4 off previously attached 25 tonne shackles on the template.
Then commence when lift supervisor determines it is safe to do so, slowly lift the template and carry out the
interface test As specified in E687.
When test is determined to be successful, slowly lift the template from the cradle and place in an appropriate
location in preparation for the other aspects of testing as specified in E687.
Disconnect the lower 55 tonne safety bow shackle, remove template lift sling assembly lay-down in an
appropriate position on the template. Taking care to ensure that all equipment is prevented from „swinging‟
and manual handling is kept to a minimum.
Methods of communication to be used :
Radio
/
verbal
/
hand signals
Steps taken to eliminate danger to personnel: barriers / permit to work procedure / tannoy / toolbox talks / lifting
plan / no conflicting tasks in the area.
(delete as appropriate)
Authorisation:
Level of Operational Control: Area Authority / Permit to Work
Engineering Support Required: No
Competent Person
Signature
Date
Reviewed by
Signature
Date
De-brief and Learning Points
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Procedure for Lifting Operations
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Appendix E
Check List for Pre-use
Mobile Crane Inspection Form
At the beginning of each shift or working day that the crane is in use, the following routine as
appropriate for the type of crane shall be carried out as a minimum.
Note: The Site Lifting Coordinator may add specialized equipment,
e.g. vacuum
lifting
equipment to this lift.
To be completed by the Site Competent Person (Deck
Comments
Foreman / Site Lifting and Rigging Supervisor)
1
Owner
2
Crane model
3
Date of last inspection
4
Date of last test
5
Current certification number
6
Makers serial number
7
Visual examination of jib sections
8
Function test of limit / safety devices
9
Outriggers, functioning properly and can take the full weight
of the crane and load
10
Daily checks specified in the manufacturer‟s handbook.
11
A check that all ropes are correctly positioned in their
sheaves and that drums are not displaced.
12
A visual check that electrical equipment is not exposed to
contamination by oil, grease, water, or dirt.
13
A visual check by inspecting relevant levels and/or
components, that no loss of fluids (e.g. lubricant oil,
coolant) is apparent.
14
A check for correct operation of all limit switches or cut-
outs and the dead man‟s handle or lever, applying caution
during checking in case of malfunction.
15
A check that the automatic safe load indicator is correctly
set and that the manufacturer‟s daily test is carried out.
16
A check that the correct air pressure is maintained in any
pneumatic control system (e.g. brakes).
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Procedure for Lifting Operations
Page 41 of 55
17
A check that lights, windscreen wiper(s) and washers
operate efficiently.
18
A visual check for security of wheels and the condition of
tyres, on wheel-mounted cranes.
A check for correct function of all crane controls without
19
load.
20
A check for correct operation of audible warning devices.
21
A check that the crane is in tidy condition and free from
tins of oil, rags, tools, or materials other that sufficient
access and egress are provided, and that appropriate fire
fighting equipment is available.
22
A check that there are no obstructions in the path of travel
of the crane.
23
Drivers experience to be reviewed.
24
Crane maintenance / certification to be reviewed.
25
Written pre-use check to be carried out prior to crane use.
Extracted from standard BS 7121 - this list does not replace the standard Crane
Driver Check List
Crane accepted/rejected (underline).
Name:
Position:
Date:
For Standard Form go to: Baku office on Eubaks5/Operations/Safety &
Environment/Checklist
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Procedure for Lifting Operations
Page 42 of 55
Appendix F
BP North Sea Lifting Rules
The following fundamental rules will be applied to all lifting operations with zero tolerance:
1.
All personnel must keep out of any area where they might be injured by a falling or shifting
load. Do not stand below loads. Never stand between loads and walls / bulkheads etc.
Always ensure an escape route is available.
2.
If a lift deviates from plan or any complication arises, the lifting operation must be stopped
and made safe. All personnel should remain in positions clear of the lift until reassessment
/ re-planning of the lift is carried out.
3.
Lifting operations will be undertaken by a minimum of three competent people: crane
operator, banksman / flagman, and load handler.
4.
The banksman / flagman 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 crane operator is responsible
while the load is in the air. The banksman must:
a) Ensure clear identification from other personnel by wearing a hi-vis jacket or waistcoat
clearly marked to indicate the authorized crane banksman.
b) Not touch the load and stand back from the load in a prominent position with a good
view of the lifting activities.
c) Remain in communication with the load handler and crane operator at all times.
d) Keep the load handler in sight during the lifting operation.
5.
The load handler must:
a) Stand clear while lifting or landing a load on the deck, while slack is taken up with or
without a load on the hook, and must confirm to the banksman that he is clear
b) Not touch a load until it is landed, or until it is below waist height, and never attempt
to manually stop a swinging load
c) Be easily identifiable, and distinct from the banksman
6.
Stacking of containers, baskets, tanks, and half heights shall not be allowed on BP
operated installations and onshore sites
Where this is not practicable, stacking requires prior permission of the relevant Performance
Unit Leader and:
a) Equipment is specifically designed for that purpose, and clearly marked as suitable for
stacking
b) Stacking is confined to pre-designated areas
c) Conduct a risk assessment of stacking operations ensuring that the risk involved is as
low as is reasonably practical
d) Stacked containers must have an additional pennant so that the crane hook can be
attached / detached while the load handler is standing at deck level
e) Stacking and unstacking is controlled by permit
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Procedure for Lifting Operations
Page 43 of 55
The attached notes are an integral part of the North Sea Lifting Rules
These rules are developed for deck lifts or deck / boat lifts using pedestal cranes on offshore
installations. They will also be applicable to similar lifts using mobile cranes, crawler cranes etc
on BP operated onshore sites.
Lifts with other devices (e.g. workshop cranes, winches, hiabs) Rules 1 and 2 will always be
applicable. Consider the application of rules
3 through 6 during job planning and risk
assessment. The rules do not specifically apply to the holding in position of items of equipment
during well servicing / wire line activities. These specialist activities should be covered by job
specific procedures, permit, and detailed risk assessment.
1. Rule 1: This includes not getting under slung loads, not getting into areas where they could
be trapped between the load and something else. Third parties not involved in the lifting
operation also have a responsibility to keep out of areas where lifting is being conducted.
2. Load Handler may also be designated as Slinger, Deck Operator or Hookman.
3. Rule 5b) In some essential lay-down areas it is necessary to manoeuvre containers into
limited landing areas adjacent to handrails, where the handrails are slightly in excess of
waist height. Where it is considered essential to continue using these lay-down areas, and
the lowest practicable risk is provided by touching the load above waist height to orient it,
installations must identify and document steps to be taken to mitigate the risk to the load
handler.
4. i) The intention is to eliminate stacking of containers and other loads as identified in rule 6.
ii) For some installations (particularly some MODUs) this may not be practicable due to
limitations on deck space. Exception to the no stacking rule is intended to cater for these
installations and not to provide a general opportunity for all installations to stack as soon as
deck space becomes congested.
iii) BUs must designate where stacking may be undertaken and document why the decision
to allow stacking was made.
iv) For those installations where no stacking is not currently practicable, a review should be
undertaken to consider what would be required to be able to operate on a no stacking
basis.
v) However, after appropriate review and documentation, particular equipment (e.g. sphere
racks) may be authorized as suitable for stacking even though stacking of other containers
is banned on that installation.
vi) Assets should reassess the design of equipment currently designated as suitable for
stacking, to confirm that it is fit for purpose both loaded and empty.
vii) Installations who intend to designate equipment or areas suitable for stacking should
consider using the MOC process to review and document the justification.
5.
These rules are not exhaustive. They reinforce behavioural aspects of lifting. Procedural
and equipment issues such as risk assessment, lifting equipment specification, lifting plans,
regulation (e.g. LOLER) are also essential to safe lifting. Crane drivers, load handlers and
check operators should comply with contractors‟ procedures, comply with regulatory
requirements, use risk assessments and toolbox talks where appropriate and must be
prepared to stop the job at any stage if the safety of the operation may be compromised.
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Procedure for Lifting Operations
Page 44 of 55
Appendix G
BP AzSPU reference document for the Selection, Application and Control of Man
Made Fiber Slings for Lifting Operations
Purpose
The purpose of this reference document is to describe the current AzSPU Policy and
Procedures for the safe selection, application and control of man-made fibre slings for lifting
operations, their subsequent inspection requirements and discard process following
completion of the lifting operation.
The use of any type of man made fiber slings in lifting operations will automatically
categorize the lift as Complicated.
Certification for this type of sling is valid for 6 months only after which time it will be removed
from service and destroyed. Man made fiber slings will not be recertified.
Introduction
All lifting operations on AzSPU sites, including those undertaken by third party contractors,
shall be implemented under the principles of Lifting Operations & Lifting Equipment
Regulations (LOLER 98/SI-2037).
Regulation 8 of LOLER stipulates that all lifting operations using Lifting Appliances and
Accessories should be carried out in a safe manner, under adequate supervision and
following a lifting operation risk assessment and predetermined plan. The degree of
planning is dependent on the lifting equipment to be used, the category of the lifting
operation and the degree of risk involved.
Lifting Sling Selection
When planning the lifting operation consideration should be given to the working load limit,
the mode of use, the nature of the load and the environment in which it is to be used.
Wherever possible, it is recommended that wire rope slings be used for lifting operations.
Never use a man made fiber sling of any type if, during the lifting operation, it can be
subjected to shock or snatch loading and never use this type of sling on boat lifting
operations.
Man made fibre slings are available in five basic formats, the two most commonly used in
lifting operations are the Flat Soft Becketed Eye type webbing sling and the Endless Round
Sling.
The Endless Round sling is the most adaptable for general-purpose use as they are more
flexible, and when choked, provide a more efficient „grip‟ on the load. Flat Soft Becket Eye
type webbing slings are more suitable for use in a “basket type” lifting mode rather than in
„choke‟ mode.
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Procedure for Lifting Operations
Page 45 of 55
Examination and Discard Criteria
Slings constructed in man-made fibers are easily damaged and can be sensitive to chemical
attack.
Strength is lost if there are any cuts, tears, abrasion, fraying and burst stitching, therefore
this sling type requires close examination by a competent person for any signs of damage
prior to every lifting operation. Endless Round Slings are manufactured with an outer
protective sheath, which prevents the ingress of chemicals and dirt, which can lead to the
deterioration of the sling fibers in service. The protective sheath also makes the examination
for defects more difficult and onerous than that of the Flat Webbing Sling.
Man-Made Fibre Endless Round Slings:
Endless Round slings shall only be used for general purpose lifting duties on the site
providing the sling has a current certificate of conformity and there is an approved lifting plan
and risk assessment for the operation. Site Lifting Coordinator shall inspect slings for
suspected or evident damage prior to use. The sling(s) shall be physically removed and
destroyed if any damage is suspected or evident. Certification for this type of sling is valid
for six months after which time it will be removed from service and destroyed.
Man-Made Fibre Flat Webbing Slings:
Flat Webbing Slings shall only be used for special lifts where the component to be lifted can
be damaged by the use of conventional wire rope slings. Flat webbing slings shall be used
for lifting duties on the site providing the sling has a current certificate of conformity and
there is an approved lifting plan and risk assessment for the operation. Site Lifting
Coordinator shall inspect slings for suspected or evident damage prior to use. The sling(s)
shall be physically removed and destroyed if any damage is suspected or evident.
Certification for this type of sling is valid for six months after which time it will be removed
from service and destroyed.
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Procedure for Lifting Operations
Page 46 of 55
Appendix H
Wind Force Scale
Wind Force in points
Wind Force, mps
Wind Force, knots
0
Calm
0-0.5 (0)
0-0.97 (0)
1
Light air
0.6-1.7 (1)
1.16-3.3 (1.9)
2
Light breeze
1.8-2.3 (2.1)
3.5-4.5 (4.1)
3
Gentle breeze
3.4-5.2 (4.5)
6.6-10.1 (8.7)
4
Moderate breeze
5.3-7.4 (6.5)
10.2-14.4 (12.6)
5
Fresh wind
7.5-9.8 (8.5)
14.5-19.1 (16.5)
6
Strong wind
9.9-12.4 (11)
19.2-24.1 (21.4)
7
High wind
12.5-15.2 (14)
24.2-29.5 (27.2)
8
Very hard wind
15.3-18.2 (17)
29.7-35.4 (33.04)
9
Storm
18.3-21.5 (20)
35.5-41.8 (38.8)
10
Hard storm
21.6-25.1 (23)
41.9-48.8 (44.7)
11
Heavy storm
25.2-29.0 (27)
48.9-56.4 (52.5)
12
Tornado
More than 29.0
More than 56.4
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Procedure for Lifting Operations
Page 48 of 55
¾ Load does not exceed dynamic and/or static
authorized by site management. They must not
Appendix I: Procedure Summary
capacities of the lifting equipment
perform other work and must never leave the
¾ Any safety devices installed on lifting
controls until a load is safely landed.
LIFTING OPERATIONS
equipment are operational
¾ All lifting devices and equipment have been
Riggers & Slingers
Lifting Appliances
visually examined before each lift by a
All personnel who use rigging equipment must
Any mechanical devices capable of raising or
competent person(s)
have completed a basic rigging training course,
lowering a load e.g. cranes, fork lift trucks,
approved by BP and appropriate to the site /
suspended cradles, powered and manual
Personnel in Charge of Lifting Operations
installation operational needs.
hoists, lever and rope hoists, beam trolleys,
Personnel in charge of lifting operations are
winches and chain blocks
responsible for ensuring:
The Load
The weight of all loads should be known and
Lifting Accessories
¾The immediate safety of all personnel
particular care must be taken when calculating
Any device which is used or designed to be
involved in the lifting activity
the weight of any plant or equipment prior to
used directly or indirectly to connect a load to a
¾That all equipment used is suitable for the
lifting, especially when it may contain a liquid (for
lifting appliance and which does not form part of
task and is within test date
example, coiled tubing reels, heat exchangers,
the load, e.g. wire, fibre and chain slings, hooks
¾That the lifting operation has been risk
etc). The crane operator must be advised of the
and fittings, swivels, shackles, eye bolts and
assessed and planned
weight of each load to be lifted.
plate clamps.
¾That the activity is executed in accordance
with the plan
Lift Planning & Risk Assessment
BP Golden Rule
¾That lifting operations are halted if an unsafe
All lifts must follow a documented procedure and
Lifts utilizing cranes, hoists, or other mechanical
situation occurs
the risks must be assessed.
lifting devices will not commence unless:
Banksman
A complex lift study is required if:
¾ An assessment of the lift has been
No lifting operation will take place without an
completed and the lift method and the
appointed banksman who will be easily identified
¾The lift involves more than one crane
equipment has been determined by a
by wearing a high visibility vest. The banksman
¾The load has a very high $ value
competent person(s)
must be suitably trained and have adequate
¾The load is above 90% of the cranes load
¾Operators of powered lifting devices are
experience for the role.
chart capacity
trained and certified for that equipment
¾The load is in excess of 20,000 kilograms
¾ Rigging of the load is carried out by a
His primary role is to guide the crane operator,
¾The load is being lifted in and out of a
competent person(s)
and must never be physically involved in the lift.
confined space
¾ Lifting devices and equipment have been
certified for use within the last 12 months (at
Crane Driver / Operator
All other lifts which do not fall under the above
a minimum)
Cranes shall only be operated by properly trained
criteria shall be covered by the Project Crane Set-
and qualified personnel who have been
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Procedure for Lifting Operations
Page 49 of 55
up and Basic Lifting Plan which is contained in
Brown
(April to October)
immediately and remain so until the devices are
the operator‟s cabin of each crane.
Purple
(October to April)
reinstated.
Certification, Examination & Testing
Cranes are to be formally inspected and
Lift Area
All lifting equipment shall be inspected and
certified every 12 months by a competent 3rd
All lift areas must be barricaded off to keep
certified. A colour coding system shall be in
party agreed by BP and contractor.
unauthorized personnel out. Loads should not
place to prove that loose equipment has been
be moved over a work area. If this cannot be
inspected at least once every
6 months.
Where possible all lifting equipment should be
done, work should be temporarily halted and
Written records of these inspections are to be
hard stamped with the safe working load
the area cleared while the lift is taking place.
maintained.
(SWL). Where it is not possible to hard stamp
The work area must be organized so that all trip
the SWL directly onto the equipment, the
or slip hazards are removed from the travel
The following colour code cycle will be used on
following alternatives are acceptable:
path before the load is suspended.
portable lifting equipment of categories 1 and 2
to indicate that they have been examined and fit
¾ Hard stamp the safe working load on
Wind Speed
for use for a six-month period:
ferrules (for example on wire rope slings)
It is the responsibility of the site / installation
¾ Hard stamp the safe working load on a
Lifting Coordinator to ensure that accurate and
Green
(October 2008 to April 2009)
metal plate securely attached to equipment
realistic wind speed readings using an
Blue
(April 2009 to October 2009)
(for example, on chain hoists)
anemometer set.
Yellow
(October 2009 to April 2010)
Safe Working Load Indicators
Lifting operations shall be suspended when
Then back to Green
All cranes must be fitted with a Safe Working
average wind speeds reach:
Load Indicator. It is the responsibility of the
NOTE: Colour Code for the 6 month period
crane driver/operator to stop lifting a load that
¾Onshore - 25 knots (12.86 m/sec)
shall be clearly identified and posted in Permit
causes the Safe Load Indicators to alarm. In
¾ Offshore - 35-40 knots (18 - 20.5 m/sec)
offices and security entrances to the site or
particular, crane drivers/operators must not use
facility.
the load radius alarms as an indication of
Cranes shall not be operated past this point
working within safe limits.
unless all of the following criteria are met:
All transit slings will be colour coded as shown
below. This will ensure that all lifting equipment
Safe Working Load Indicators, or any other
¾The lifting equipment (crane) is rated by the
is easily identified and kept separate from the
alarms fitted to lifting appliances shall not be
manufacturer to operate in higher winds
transit slings. The control and re-certification of
disconnected or made unserviceable at any
¾ All risks have been identified and mitigation
unused transit slings shall be the responsibility
time whilst the equipment is in service.
measures are in place and documented
of the site manager / Site Controller / Offshore
Wherever such warning devices have been
¾The responsible Area Authority has
Installation Manager.
disconnected or made unserviceable, the lifting
reviewed and approved all documentation
equipment shall be taken out of service
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Procedure for Lifting Operations
Page 50 of 55
¾The operation is immediately stopped if
Man-riding Operations
Is there a documented
conditions
deteriorate
beyond those
Due to specific verification requirements, the
procedure?
identified in the risk assessment
suitability of cranes for man-riding shall be
Are you experienced with all the
¾The work is restricted to low level lifts
assessed by Site Manager‟s / Site Controller‟s /
lifting equipment to be used?
¾The operating limitations shall be clearly
Offshore Installation Manager‟s and Site Lifting
Has the load been checked and
displayed in the cab of the crane.
Coordinator‟s for each and every operation.
made ready for lifting (e.g. sea
fastenings released, hold down
Outriggers
Tag Lines
bolts removed)?
Statistics show that at least
50% of crane
Tag lines shall be used as and when required
Do you have the experience to lift
incidents occur because the mobile crane or
during lifting operations to control the load from a
a load of this weight?
outriggers are not set-up properly.
Specific
safe distance. When used the operation shall be
Is the lifting area free from
hazards that can cause or contribute to failure or
risk assessed. A tag line is used to enable the
obstructions and other possible
collapse include:
load to be moved and positioned by allowing the
hazards?
rigger to stay out of harms way. The minimum
Can the lifting operation be
¾ Failure to extend the outriggers fully
diameter of tag line shall be 16mm. Tag lines
carried out without the use of
¾ Not extending all outriggers
should never be looped around hands, arms or
webbing slings? Or is a site-
¾ Failure to get completely “off-rubber”
other parts of the body. General purpose gloves
specific procedure for the use of
¾ Not accounting for poor ground conditions
are to be worn when using tag lines.
webbing slings in place?
¾ Failure to level the crane
If the answer to any of the above is “NO”, go
To prevent slips, trips and falls when guiding a
to Part 2 (Simple Lift)
Poor conditions reduce the amount of load a
load with a tag line, the travel path must be clear
crane can safely place on the outrigger pad.
and safe before the load is suspended.
Simple Lifts (part 2)
Because of this, all outriggers must have
CHECKLIST
YES
NO
additional
“blocking‟ under them. Blocking will
Lift Categories
Do you know the weight of the load
help disperse the weight of the crane and its load
To assist with the risk Assessment process, lifting
and does the lifting operation
over more ground area than does the fixed pads.
operations have been divided into four
appear to be straightforward?
categories, which are Routine, Simple,
If the load is heavier than you
Leveling - If the outrigger pad is set down on
Complicated, and Complex.
normally handle, do you have the
unleveled “blocking”, the outrigger pad may slide
relevant permission and/or permit?
off when under load, causing the crane to tip.
Lift Categorization Assessments are as follows:
Is there a crane or certified support
steelwork (e.g. runway beam or
Excavations - Cranes must be set-up so that no
Routine Lifts (part 1)
lifting eye) directly above the load?
outrigger is closer than 1.5 times the depth of the
CHECKLIST
YES
NO
Does the load have certified lifting
excavation.
Has the lifting operation been
points (lifting eyes/collar eyebolts,
performed before?
etc.) fitted and if not, can slings be
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Procedure for Lifting Operations
Page 51 of 55
wrapped around easily (e.g. no
CHECKLIST
YES
NO
The load is classified as heavy (as
sharp edges, load not fragile, etc.)?
Is the lift stable? (i.e. centre of
specified by Site Lifting
Is there ample headroom for the
gravity below the lifting points and
Coordinator*) and is not being
lifting appliance and slings?
not offset) .
transported in CCU
Is the lift stable (e.g. centre of
Is the centre of the gravity for the
The lift involves a floating crane
gravity below lifting points)?
load viewed as balanced and
The load is critical to business
Is the lift balanced (e.g. centre
acceptable?
The lift is in a confined space
gravity in the middle) or fitted with
Can the lift be performed without
and/or an area with very restricted
special slings to compensate?
cross-hauling or being restrained?
headroom.
Is the load free to be lifted (e.g. sea
Does the load have specific lifting
Use of non-certified structural
fastenings released, all hold-down
attachments?
components, which require
bolts removed, not jammed, etc.)?
Is the load robust? (not fragile)
engineering calculations
Is the removal route clear of any
Does the load have a limited
Personnel Transfer / Man-riding
obstructions?
surface area that will not cause
activity where no approved site
Can the removal (lift, transfer, and
instability in the wind?
specific procedures exist
landing) be performed without cross
Does the load require only one
hauling?
crane? e.g: no tandem lifting
Checklist Prior to Lifting Operation
Taking
Is there suitable lay down area and
Can the lift be performed without
Place
does the load come within the
rotation?
QUESTIONS
YES
NO
allowable load bearing capacity of
Uncertified structural components-
the ground/deck?
can the lift be carried out safely
Lift has been planned and risk
Are you experienced in using all the
without the need for MHC
assessed and Crane Set-up
lifting equipment and gear
engineering calculations
booklet has been completed
involved?
If the answer to any of the above is “NO”, go
The weight of the load is known
Can the lifting operation be carried
to Part 4 (Complex Lift)
by the crane operator and the
out without the use of Webbing
person in charge
Slings? Or is a site specific
Complex Lifts (part 4)
Wind speed is known and within
procedure for the use of webbing
acceptable limits
slings in place?
REASONS FOR REQUESTING
Crane operator certification is
YES
NO
ENGINEERING INPUT
current
If the answer to any of the above is “NO”, go
The lifting operation involves divers
Banksman is easily identifiable
to Part 3 (Complicated Lift)
The lifting operation is sub-sea
“High Viz” jacket
Complicated Lifts (part 3)
The load will be travelled over
Banksman is not physically
unprotected process plant and
involved in the lift, guiding crane
machinery
operator only
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Procedure for Lifting Operations
Page 52 of 55
Adequate
means
of
Is the crane in good condition,
If the answer to any of the above is “NO”,
communication between the crane
regularly inspected and maintained
“DO NOT” carry out man-riding operations
operator and banksman
and are records kept to
Equipment has been inspected
substantiate this?
and is painted the correct colour
Are all the safety features and
Lift area is barricaded off
systems working properly? e.g.
Lift
will not endanger other
Rated Capacity Indicators (RCIs),
operations
overhoist limiters, etc.
Lift area is well organized and slip
In the event of a complete power
and trip hazards have been
failure, will the crane maintain the
removed
load in a safe condition (e.g. do the
Outriggers are in “full out” position
brakes fail to the applied position)?
Outriggers are correct distance
Are the brakes applied
from excavations
progressively (e.g. to avoid shock
Outriggers are set on “blocks”
or snatch loading)?
Crane is level
In the event of a complete power
failure can the personnel be
Tag line is connected to load and
used to control load
recovered safely? (Is there a
recovery plan in place).
Checklist for Suitability of Cranes for Man-
In the event of a primary brake or
transmission system failure, will
riding Operations
the load be prevented from free-
QUESTIONS
YES
NO
falling (e.g. is there a secondary
braking system or does the
Has it been established that no
transmission system have
other viable option of carrying out
hydraulic retardation to prevent
the work is available?
this)?
Are all the necessary certificates
Is the crane fitted with an
for the crane wire ropes, slings and
emergency stop, which is located
other associated equipment
for immediate operation by the
current?
crane operator?
Has the crane and associated
Is the crane so designed that
equipment been thoroughly
inadvertent freefall is prevented
inspected by a suitably qualified /
when the drive train is in motion or
competent person within the last 6
the hook is loaded?
months?
Control Tier:
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Procedure for Lifting Operations
Page 2 of 55
APPENDIX J - Feedback & Improvement Suggestions
Procedure Feedback & Improvement Suggestions
Project Name: ______________________________
Date: ______________________________________
Name:_____________________________________
Badge Number: _____________________________
Procedure Reference: ________________________
Procedure Title: _____________________________
Improvement Suggestions (Write below your improvement suggestions)
Signature: _____________
Forward your Improvement Suggestion to Safety &
Compliance Systems Manager, Hyatt Tower 2, 6th Floor
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Procedure for Lifting Operations
Page 3 of 55
Revision/Review Log
Revision Date
Authority
Custodian
Revision Details
06 July 2004
Central
Lifting
Initial issue as controlled document
Engineering Senior
Technical
Authority
Authority
18 June 2007
Steve Grittner
John Thompson
Table of Contents:
(Central
Eldar
Section 2 is now Definitions & Abbreviations.
Engineering Senior
Fiahardinov
All other sections moved forward, but remain
Authority)
Barry Riddell
the same headings.
(Lifting
General:
Technical
Throughout the procedure the document
Authorities)
control numbering for referred procedures
has been changed.
Section 1. Introduction:
1.1 is now Document Purpose. 1.2 is now
Document Scope, with first 4 paragraphs
added. The following are new sub-sections:
1.3 is now Stopping Unsafe Work. 1.4 is now
Deviations. 1.5 Document Review. 1.6 is now
SSOW Specific Cross References. 1.7 is now
BP Golden Rules of Safety 1.8 is now
Language Facilitation. 1.9 Procedure
Summary.
Section 2. Definitions:
This is a new section
Section 3. Lifting equipment:
First paragraph includes Safe Working Load.
3.1 CATEGORY 1. Now combined with
CATEGORY 2. 3.4 CATEGORY 4. 2
additional bullet points. 3.5 CATEGORY 5.
This section completely re-worded. 3.6
CATEGORY 6. Additional paragraph added.
3.7 Man-riding. This sub-section has been
deleted.
Section 4. Examination Philosophy:
4.1 Examination of Portable Lifting
Equipment. Additional paragraph entered. 4.2
Examination of Fixed Lifting Equipment. Last
paragraph removed. 4.4 Examination of
CCU‟s. This sub-section completely re-
worded. 4.5 Examination of Mobile lifting
Equipment. This sub-section completely re-
worded.
Section 5. Reports / Records:
Paragraphs re-worded with bullet point
added. Section 6. Control Processes:
6.1 Rigging Loft (storage area). New sub-
section.
6.2 Colour Coding. 3 paragraphs
added. 6.3 Control of Portable Lifting
Equipment. Examination and colour code
periods updated. Also “NOTE” added. 6.8
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Procedure for Lifting Operations
Page 4 of 55
Control of Third Party Contractor Lifting
Equipment. Additional paragraph added. 6.10
Control of Webbing & Round Slings. Section
added on control of man-made fibre slings.
Section 7. Competency:
7.1 Competencies and Training of Personnel.
Levels of competency updated on the matrix.
Section 8: Roles and Responsibilities:
2 bullet points added to the generic
stakeholders. 8.1 Site Manager/Site
Controller/Offshore Installation Manager. This
is a new addition to R&R‟s. 8.2 Area
authority. This is a new addition to R&R‟s. 8.4
Rigger / Slinger. 1 bullet point added. 8.5
Crane Operator. Additional paragraph added.
8.8 Lifting Inspector. 5 bullet points added.
Section 9. Communications
New section
Section 10. Risk Assessment and
Planning of Lifting Operations:
10.1 Strategy. Additional paragraph added
after All lifting operations shall be:
Appendices:
3 appendices included to the document as
follows:
Appendix B: Inspection and Certification of
Temporary or New Cranes
Appendix I: Procedure Summary
Appendix J: Feedback & Improvement
Suggestions
15 December
Chris Houghton
Eldar Fiahardinov
Table of Contents:
2008
(AzSPU Engineering
(Lifting Technical
Paragraph 1.5 is now “Medical”. All other
Authority)
Authorities)
paragraphs moved forward, but remain the same
headings.
General:
New paragraph 1.5, Medical, is added to Section
1.
Paragraph 3.1, Portable Lifting Equipment.
Clarification Note on 4 leg sling set is added.
Paragraph 3.5, Transit Slings, is reworded.
Paragraph 4.4, Examination of CCU,s - new
wording is added.
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Procedure for Lifting Operations
Page 5 of 55
Paragraph 10.1, Strategy - new wording in regard
to Integra Team is added.
Appendinx A - additional definition is given to
Heavy Lift.
Appendix D
02 February
Chris Houghton
Eldar Fiahardinov
Generic Lifting Plan, Simple, for Offshore and
2009
(AzSPU Engineering
(Lifting Technical
ASCO base / quay side is added to the
Authority)
Authorities)
Procedure.
Chris Houghton
Eldar Fiahardinov
07 October
Minor change was made to Paragraph 6.6 in
(AzSPU Engineering
(Lifting Technical
2009
regard to relevant preliminary permission in
Authority)
Authorities)
case of Drilling & Completions.
Extension date of procedure requested due to
Chris Houghton
Eldar Fiahardinov
26 April 2010
need for clarity with standards
(AzSPU Engineering
(Lifting Technical
Authority)
Authorities)
05 August 2010
Yuliy Zaytsev
Eldar
Additional time for research requested in line with
Safety & Compliance
Fiahardinov,
crane operators qualifications criteria
Systems Manager
Lifting Operations
Technical
Authority
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Procedure for Machine Guards
Page 1 of 11
Procedure for Machine Guards
AZSPU-HSSE-DOC-00057-2
This number supersedes UNIF-HSE-PRO-151-C1
Authority:
AzSPU Safety & Compliance
Custodian:
HSE Systems / CoW Adviser
Systems Manager
Scope:
AzSPU
Document
Administrator:
MS Document Controller
Issue Date:
05 October 2004
Issuing Dept:
Safety & Compliance Systems
Revision Date:
14 August 2009
Control Tier:
2
Next Review
14 February 2011
Date:
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Procedure for Machine Guards
Page 2 of 11
TABLE OF CONTENTS
1
PURPOSE / SCOPE
3
1.1
PURPOSE
3
1.2
SCOPE
3
2
DEFINITIONS
3
3
GENERAL REQUIREMENTS
4
3.1
BP AZSPU REQUIREMENTS
4
3.2
LEGISLATION & STANDARDS
4
3.3
STOPPING UNSAFE WORK
4
3.4
DEVIATIONS
4
3.5
LANGUAGE FACILITATION
5
4
RESPONSIBILITIES
5
4.1
SITE MANAGER (SM) / SITE COORDINATOR (SC) / OFFSHORE INSTALLATION MANAGER
(OIM) 5
4.2
AREA AUTHORITIES (AA)
5
4.3
PERFORMING AUTHORITIES (PA)
5
4.4
ALL PERSONNEL
5
5
MACHINE GUARD REQUIREMENTS
6
5.1
ALL MACHINERY
6
5.2
AUTOMATIC MACHINERY
6
5.3
SELECTION AND USE OF GUARDS
6
5.4
GUARD MATERIALS, CONSTRUCTION AND FITTING
7
5.4.1
Materials
7
5.4.2
Design, Construction and Fitting
7
5.4.3
Retro-fitting of Emergency Stop Controls
7
5.5
GUARD REMOVAL
8
5.6
RISKS FROM UNGUARDED AND POORLY GUARDED EQUIPMENT
8
6
KEY DOCUMENTS REFERENCES
9
REVISION/REVIEW LOG
10
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Procedure for Machine Guards
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1 PURPOSE / SCOPE
1.1 PURPOSE
This document contains information on:
The conditions and situations where machine guards must be in place and
used
The reasons for installing machine guards and the conditions that must exist
before they may be removed
The type of guards and protective devices available and the considerations
governing their choice and design.
1.2 SCOPE
The contents of this procedure are applicable to all AzSPU owned and managed
sites
/ installations in Azerbaijan and Georgia. Contractors/vendors working on
AzSPU owned or managed sites / installations are also responsible for alignment
with this procedure.
This document does not replace the procedures prepared and adopted by specialist
contractors. Neither does it supersede any national regulatory requirements.
This procedure contributes to compliance with the “HSE expectations” contained in
“getting HSE right”, the „Golden Rules of Safety‟ and the Control of Work (CoW)
standard that the Hazards associated with BP activities are identified and that the
risks are assessed and managed.
All guidelines contained shall be regarded as the minimum requirements for BP
owned or managed sites / installations in Azerbaijan and Georgia.
The scope covers defined activities of BP AzSPU and Contractors at all BP AzSPU
sites and installations.
2 DEFINITIONS
Refer to document AzSPU-HSSE-DOC-00021-2 HSE Definitions for definitions
common to this Procedure. Definitions specific to the Procedure are included below.
SM
Site Manager
SC
Site Controller
OIM
Offshore Installation Manager
AA
Area Authority
PA
Performing Authority
ALARP
As Low as Reasonably Practicable
COW
Control of Work
AzSPU
Azerbaijan Strategic Performance Unit
ALARP
As Low as Reasonably Practicable
SSoW
Safe System of Work
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3 GENERAL REQUIREMENTS
3.1 BP AZSPU REQUIREMENTS
It is a company requirement that all tasks are subjected to an assessment of risk to
demonstrate that risks have been reduced to as low a level as reasonably
practicable (ALARP). This can be achieved by complying with the BP‟s existing
standards. Where compliance with BP standards cannot reasonably be achieved, a
formal level 2 Risk Assessment will be undertaken to identify any additional controls
and demonstrate that risks remain as low as reasonably practicable. Whether by
compliance with BP Standards or through level 2 Risk Assessment, the BP Golden
Rules of Safety must be complied with. Golden Rules are non-negotiable.
3.2 LEGISLATION & STANDARDS
This procedure complies with applicable national law. Applicable national law is
national law as amended by project specific agreements, e.g. the ACG Production
Sharing Agreement (PSA), and relevant International Conventions, if any, in force in
Azerbaijan or Georgia, as applicable.
In the absence of national legislation, or where national legislation is inconsistent
with the requirements of project specific agreements, BP Group Standards or
applicable requirements from UK or US legislation will be complied with.
Where requirements conflict, legal advice has been obtained and a defendable
compliance position adopted.
The standards and practices contained in this procedure are consistent with those
internationally recognized within the petroleum industry.
3.3 STOPPING UNSAFE WORK
To stop the continuation of potentially unsafe work at the earliest possible stage, the
Control of Work (CoW) Policy and this procedure for Machine Guards make it very
clear that all personnel are obliged and have the authority to “STOP” the work that
they consider to be unsafe.
3.4 DEVIATIONS
This procedure is written in sufficient detail that it should be able to be applied
consistently at all sites / installations. There may still be the requirement for some
local rules covering site / installation specific logistical/administrative arrangements
and local variations in responsibilities to reflect differences in organisational
arrangements. These local rules should not deviate from the core processes within
this document. Any form of deviation from this procedure, including but not limited to
local rules, shall be requested and authorised in accordance with SSOW, Deviations
from Regulations and Procedures (Doc. No: AZSPU-HSSE-DOC-00011-2).
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3.5 LANGUAGE FACILITATION
Due to the various languages spoken at sites / installations, there is a necessity to
assist all with “an ease of understanding”.
4 RESPONSIBILITIES
4.1 SITE MANAGER (SM) / SITE COORDINATOR (SC) / OFFSHORE INSTALLATION
MANAGER (OIM)
The Site Manager
/ Site Controller
/ Offshore Installation Manager shall be
responsible and accountable for the application of this procedure in his area of
responsibility, He shall ensure:
That adequate numbers of Competent responsible persons are appointed to
manage and maintain the requirements of this procedure
Note: Guards and safety devices shall be checked following any repairs or
modifications.
4.2 AREA AUTHORITIES (AA)
Area Authorities are responsible for ensuring that:
That the requirements of this procedure are adhered to for all work involving
leak testing activities in his area of responsibility
All fixed machinery in their area is guarded in accordance with this procedure
All machine guards and safety devices in their area are routinely checked and
maintained in working order
4.3 PERFORMING AUTHORITIES (PA)
Performing Authorities are responsible for ensuring that all portable equipment that
is used by the personnel under their control conforms to this procedure.
4.4 ALL PERSONNEL
All personnel are responsible for:
Ensuring that the machinery and equipment they use or maintain has all the
necessary guards in place and that all guards are properly fitted
Immediately reporting to their supervisor if they believe a machine is in a
dangerous condition or if any guards or protective devices are faulty
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Procedure for Machine Guards
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5 MACHINE GUARD REQUIREMENTS
5.1 ALL MACHINERY
Guards must be fitted to those parts of a machine wherever:
Cutting, shaping or boring of any material is performed
There are components that transmit energy, including:
o flywheels
o pulleys
o belts
o cranks
o gears
o couplings, etc.
There are moving parts which can be reciprocating or rotating, including feed
mechanisms and other accessories
Debris or products may be emitted / ejected that present a danger to the
operator and /or nearby personnel, e.g., deflectors for relief valves, screens for
bench grinders and lathes, etc.
In addition, where deemed necessary, guardrails or barricades may be placed
around equipment to prevent personnel from getting close to it.
5.2 AUTOMATIC MACHINERY
Guards must be installed on equipment that can start automatically (and / or without
warning) such as air compressors, diesel sets, etc.,
In addition, warning signs such as
“Caution
- This machine can start
automatically!” shall be posted near all such equipment.
5.3 SELECTION AND USE OF GUARDS
Fixed and/or adjustable guards such as covers and plates are the most common
type of guard and should be used wherever possible. The guards should be properly
fastened in place with screws or nuts and bolts which need tools to remove them.
Interlocks, designed to shut down the machine if protective covers are opened or
removed, should be used where fixed guards are not reasonably practicable and the
equipment user / maintainer needs regular access to parts of the machine. The
interlock should ensure that the machine cannot start before the guard is properly
replaced / closed and must also ensure that the machine will stop if the guard is
opened while the machine is moving.
Two-hand controls are designed to prevent the operator „reaching in‟ while the
machine is running and should therefore be located at a safe distance from the
danger area.
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Emergency stop controls should be located within easy reach of the operator,
particularly on larger machines so that they can be operated quickly in an
emergency.
In some cases, presence sensing devices, for example, photoelectric, and
pressure sensing devices may be used instead of fixed guards or interlocks.
However these devices must be regularly checked to ensure their continuing
operation and effectiveness.
Portable power tools must be equipped with manufacturers fitted means of power trip
in case of operator or equipment failure (e.g. „dead-man‟ switchers).
5.4 GUARD MATERIALS, CONSTRUCTION AND FITTING
5.4.1 Materials
The materials from which the guard is manufactured should be carefully chosen for
suitability. For example:
Plastic is easy to see through but may be easily scratched, damaged or
shattered
If wire mesh or grating is used, it should not have holes that are large enough
to allow access to the danger area or large enough to allow the passage of
debris
5.4.2 Design, Construction and Fitting
All guards shall be designed, constructed and fitted so that they:
Protect the operator and any other personnel from the equipment (especially its
moving parts)
May not be easily removed or tampered with, e.g., they must be firmly secured
to the machine
Can withstand the conditions of normal use
Allow the machine to be cleaned safely
Prevent foreign objects from falling onto moving parts, e.g., small tools, nuts,
bolts, etc
Do not present sharp or jagged edges, i.e., they should be rolled and / or
bolted
Do not create interference which would hamper personnel from performing
their assigned tasks quickly and comfortably
Do not obstruct lubrication points and feeds in such a way that the guard must
be removed before these components can be properly accessed.
5.4.3 Retro-fitting of Emergency Stop Controls
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Procedure for Machine Guards
Page 8 of 11
MOC must be completed, approved and authorised.
Note: Before fitting emergency stop controls to machines that have not previously
had such controls fitted, it is essential to check that the emergency stop
controls do not in themselves present new risks. For example, some
machines require the power supply to be on in order to operate the brakes.
This power might be lost if the machine is stopped using the emergency
stop control.
5.5 GUARD REMOVAL
Machine guards shall only be removed by competent and experienced personnel for
maintenance and repair purposes.
Whenever guards are removed for maintenance or repair:
The removal shall be carried out under a Permit to Work
The energy source to the machine must be isolated and the switch, button,
lever etc., must be locked out and tagged before the guard can be removed
All guards must be in place before the lock and tags can be removed.
Machine Guards shall be inspected as a part of PMP (Preventive Maintenance
Programme).
5.6
RISKS FROM UNGUARDED AND POORLY GUARDED EQUIPMENT
Moving parts of equipment, if not guarded, are extremely dangerous to operating personnel
and to any other personnel working in the immediate vicinity.
Warning: Any machine part, function or process that may cause injury must be
guarded to prevent contact with personnel.
The risk of accidents involving machinery may be caused by entanglement, shearing,
crushing, trapping, and cutting, etc. These accidents may occur due to:
A lack of guards or poor guards on machines and equipment
A failure to keep guards and safety devices properly maintained so that machines or
equipment become unsafe
Provision of inadequate controls or the wrong type of controls so that equipment
cannot be turned off quickly and safely or it may be started accidentally.
The hazards from machinery shall be identified as part of Risk Assessment. Such Risk
Assessment shall evaluate the nature of an injury, its severity and likelihood of occurrence
for each hazard identified. This will enable employee to decide whether the level of risk is
acceptable or if risk reduction measures are needed. In most cases the objective of risk
reduction measures is to prevent contact of part of the body or clothing with any dangerous
part of the machine.
The measures taken to prevent access to the dangerous parts of the machinery are ranked
as follow in order to be implemented, where practicable, to achieve an adequate level of
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Procedure for Machine Guards
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protection:
a) fixed enclosing guards
b) other guards or protection devices such as interlocking guards and pressure mats
c) protection appliances such as jigs, holders and push-sticks etc
d) the provision of information, instruction, training and supervision.
6 KEY DOCUMENTS REFERENCES
This procedure shall, where appropriate, be used in conjunction with this suite of AzSPU
Procedures referenced below.
Document Number
Title of Procedure
AZSPU-HSSE-DOC-00011-2
Procedure for Deviations
AZSPU-HSSE-DOC-00060-2
Procedure for Permit To Work
AZSPU-HSSE-DOC-00063-2
Procedure for Task Risk Assessment
AZSPU-HSSE-DOC-00048-2
Procedure for Energy Isolations-Electrical
AZSPU-HSSE-DOC-00053-2
Procedure for Hot Work Naked Flame
AZSPU-HSSE-DOC-00061-2
Procedure for Personal Protective Equipment
AZSPU-HSSE-DOC- 00002-2
Procedure for Control of Work
AZSPU-HSSE-DOC-00072-2
Review/Revision Process for HSE Tier 2 Procedures - TOR
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