Document Title: Rigging Equipment Management Guideline

COPI Doc No.: ID-G-BU-00000-00000-00315

Originator: COPI
COPI Group Owner: UO- Asset Integrity - OEE
Area: General
Location: General
System: General
Document Type: Standard Specification
Discipline / Subdiscipline: General / General
Old COPI Document No.: COPI-HS-ST-00001 Sec. L.003 Lifting Gear Certification

ID-G-BU-00000-0000
0-00315.pdf

PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY
INFORMATION BELONGING TO CONOCOPHILLIPS INDONESIA AND
MUST NOT BE WHOLLY OR PARTIALLY REPRODUCED
NOR DISCLOSED WITHOUT PRIOR WRITTEN
PERMISSION FROM CONOCOPHILLIPS INDONESIA

Wawan
Gunawan/
Arianto B Didik Idham HS Not
5 IFU April 2015 Issued for Use Muhdi
Nugroho Wibisono Purba Req’d
Sujatmiko/
Tasdikin
Wawan
Nugroho Gunawan/
September Didik Idham HS Not
4 IFU Issued for Use Aryanto/Iman Muhdi
2013 Wibisono Purba Req’d
Sugihartoto Sujatmiko/
Tasdikin
December Duncan Anggiat M. Patrick Phil
3 IFU Issued for Use Rune Tufta
2010 Fraser Sihotang Wolfe Webb
Niels
Andre Boriyantoro/ Aty Not
2 IFU 3 Dec 08 Issued for Use Faisal
Indrayana Supriyadi Req’d
Bonny S.P

Nizar S/ Anggiat M.S/ James D.

Bob Stubbs/ Tom
1 IFU 13 Oct 06 Issued for Use T./ Nindyo
Andre I Bonny S.P Nindyo S Wellman
S.
Snr.
Unit Owner VP Ops
Rev Status Issue Date Reason for Issue Prepared Checked Manager
Approvals
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Standard Specification: ID-G-BU-00000-00000-00315 Rev. 5
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ConocoPhillips Indonesia Page 2 of 11

Revision Sheet
ConocoPhillips Indonesia Inc. Ltd

REVISION DATE DESCRIPTION OF CHANGE

0 Feb 2003 Issued for Use

Issued for Used (add new Lifting equipment and integrated with rigging
1 13 October 2006
lofts procedure)
Revise 5.9 Rigging Lofts
A secure and often portable container/box (for offshore) or dedicated
specific storage area (for onshore) which contains a selection of certified
loose lifting gear, for use in lifting operations either on an offshore
installation or similar work site.
The rigging lofts are maintained by QA/QC personnel in onshore and
offshore.
2 3 Dec 2008
In order to close CAP 3-4 NC 14 Corp Audit Suban Dayung:
7.1 • Safe Working Load - All lifting gear shall have their SWL marked in
metric units (1 tonne = 1,000 kg)

7.5 A register of the lifting gear governed by this standard shall be

maintained up-to-date by QA/QC personnel in onshore and offshore and
accessible for every user.
Amended and incorporated into the suite of procedures created for the
3 December 2010
Cranes & Mechanical Handling Improvement Project
4 September 2013 Re-Numbering and Update NSL Matrix in the Appendix C
Revise according to color code application, Appendix C update based on
5 April 2015
NSL 2014 Edition

Additional Approvers (If Applicable)

Name Designation Signature Date

Adam Febrian Maintenance Manager

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Contents
Contents .................................................................................................................................................... 3
Appendices ............................................................................................................................................... 3
1 Purpose ................................................................................................................................. 4
2 Reference.............................................................................................................................. 4
3 Application ........................................................................................................................... 4
4 Responsibilities/Accountabilities ...................................................................................... 4
5 Potential Hazards ................................................................................................................. 4
6 Documentation of Lifting Gear ........................................................................................... 4
7 Definitions ............................................................................................................................ 4
7.1 Lifting Equipment ................................................................................................................... 4
7.2 Certification ............................................................................................................................ 4
7.3 Load Test ............................................................................................................................... 5
7.4 Safe Working Limit (SWL) ..................................................................................................... 5
7.5 Inspection............................................................................................................................... 5
7.6 Pre-use Inspection ................................................................................................................. 5
7.7 Qualified Inspector ................................................................................................................. 5
7.8 Contractor Equipment ............................................................................................................ 5
7.9 Rigging Lofts .......................................................................................................................... 5
7.10 Color Code ............................................................................................................................. 5
8 Inspection and Certification ............................................................................................... 5
8.1 Initial Inspection & Certification .............................................................................................. 5
8.2 Re-inspection & Re-Certification............................................................................................ 6
8.3 Frequency of Inspection and Certification ............................................................................. 6
8.4 Inspection Prior to Use .......................................................................................................... 6
8.5 Proof Load Testing ................................................................................................................ 6
8.6 Inspection............................................................................................................................... 6
8.7 Synthetic Slings ..................................................................................................................... 7
8.8 Wire rope slings ..................................................................................................................... 7
8.9 Additional Considerations ...................................................................................................... 7
9 Identification and Records .................................................................................................. 7
10 Equipment which has failed Routine Inspection .............................................................. 8
11 Repair or Modifications to Lifting Equipment ................................................................... 8
12 Contractor / Sub Contractor Equipment ........................................................................... 8

Appendices
Appendix A - Referenced Documents ....................................................................................................... 9
Appendix B – Lifting Equipment List ...................................................................................................... 10
Appendix C – Lifting Appliances ............................................................................................................. 11
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1 Purpose
The purpose of this document is to set out guidelines for the operation, inspection and
maintenance of COPI lifting equipment. It is the intent of this guideline that all lifting
equipment shall:
 Have relevant certification documents and be certified for use
 Be inspected and load-tested as appropriate prior to being put into service
 Be visually inspected each time prior to use,
 Be used in accordance with its design
 Be maintained in good condition for safe use.

2 Reference
This guideline should be read and executed with reference to the COPI Rigging, Lifting &
Mechanical Handling Standard document, ID-G-BU-GG0-POL-GN-00-00010.

3 Application
All lifting equipment used by Company, contractors and sub contractors when performing
lifting operations with Company materials and equipment while working at Company
Facilities or under Company direction.

4 Responsibilities/Accountabilities
Vice President Ops shall be accountable for the COPI rigging equipment management
guideline. Senior Managers, or their delegates, shall be responsible for the
implementation of the guideline.

5 Potential Hazards
Lifting equipment failure under load may cause injury to personnel, damage to process
facilities, equipment or materials and adversely impact the environment.

6 Documentation of Lifting Gear

A register of lifting equipment with the respective inspection dates and certificates for all
lifting equipment must be maintained by the operating areas in an updated condition.

7 Definitions
7.1 Lifting Equipment
Lifting equipment comprises both lifting appliance such as cranes, forklifts, suspended
cradles, hoists, beam trolleys, beam clamps, blocks, winches and runway beams etc. and
lifting accessories which connect a load to the lifting appliance and are not part of the
load such as wire rope slings, chain slings, man-made fiber slings, hooks and fittings,
swivels, shackles, eye bolts, rigging screws, wedge sockets, plate clamps, etc. Lifting
equipment also includes items that are used during lifting such as cargo containers,
barrel clamps or hooks, tote tanks, spreader bars, etc. An indication of special items
appears in Appendix B.
7.2 Certification
An assurance by the manufacturer or by a Qualified Inspector, that the lifting equipment
is safe for use. This is generally accomplished with certification documentation received
with the purchase of the particular piece of lifting equipment. Qualified Inspector shall be
MIGAS Crane Inspector certified as a minimum qualification.
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7.3 Load Test

The testing of a piece of equipment to a predetermined load to ensure that the equipment
is capable of being used at the Working Load Limit (WLL) stated for that piece of
equipment. Testing shall be performed and witnessed by a Qualified Inspector, usually a
third party. Proof-load test factors are shown in Appendix C.
7.4 Working Load Limit (WLL)
The maximum load, as certified by Qualified Inspector and/or equipment manufacturer,
which an item of lifting equipment may raise, lower or suspend under particular service
conditions. The Working Load Limit must never be exceeded.
7.5 Inspection
This is the examination of a piece of lifting equipment to provide assurance that it
continues to be safe for use at the stated WLL. The inspection will include a visual check
of its condition and may involve Non-Destructive Testing, at the discretion of the
Inspector.
The inspection should be done by third party inspectors who are familiar with the lifting
equipment and how it is used.
7.6 Pre-use Inspection
The visual inspection that is done prior to the use of a piece of lifting equipment which
ensures that the lifting equipment is appropriate for the planned use, verifies that it has
not been damaged in one of its prior uses and that it has the WLL, identification tag and
color code in accordance with the current installation color code.
7.7 Qualified Inspector
A person or agency who has the accreditation from government regulatory agency or
manufacturer to provide inspection, testing and/or certification services to COPI. The
qualified inspector will have the requisite knowledge and experience in both theoretical
and practical use of the type of equipment under examination to certify with confidence
that the inspected lifting equipment is free of defects and suitable for the duty for which it
was designed.
7.8 Contractor Equipment
This is defined as lifting gear owned or used by Contractors, including all sub-contractors,
on Company Facilities or with Company equipment and materials. This lifting gear shall
comply with the intent of this standard. Contractors must use this standard or provide a
Company approved equivalent procedure that ensures compliance with this standard.
Proof of certification and ongoing re-certification must be produced upon demand.
7.9 Rigging Lofts
A secure (portable where required) container/box (for offshore) or dedicated specific
storage area (for onshore) which contains a selection of certified loose lifting gear, for use
in lifting operations.
7.10 Color Code
A method of marking lifting equipment usually, but not always, with paint to give an
immediate visual indication of present certification status to the user.

8 Inspection and Certification

8.1 Initial Inspection & Certification
Prior to its initial use, all lifting equipment (lifting appliances and lifting accessories):
 Shall be inspected,
 Shall receive a unique identification number and / or tag
 Shall be marked in accordance to the relevant color code (lifting accessories only).
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In addition, all lifting equipment and lifting accessories should have documentation in
accordance with Appendix C – Lifting Equipment Matrix. The documentation shall provide
assurances to the Qualified Inspector that the lifting equipment has the necessary
material strength to be used at its WLL. This is accomplished by considering supporting
documentation such as material certification test results and/or the performing of a load
test as appropriate. Once it has passed this inspection, it is marked with the appropriate
color code for lifting accessories.
Equipment that has been disassembled and reassembled, repaired or modified shall
have a re-inspection prior to it returning in service. Equipment that fails this inspection will
not be permitted for use on Company Facilities and should be returned to the supplier or
discarded.
8.2 Re-inspection & Re-Certification
All lifting equipment shall be re-inspected and re-certified by a qualified inspector from an
independent third party at regular intervals.
If the inspection reveals any defect that would prevent it from being used in a safe
condition, the lifting equipment (lifting appliance or lifting accessories) shall be withdrawn
from service and quarantined from further use. It is then either discarded or repaired and
re-inspected to ensure that it is capable of being used at its rated Working Load Limit
(WLL) as originally certified.
8.3 Frequency of Inspection and Certification
Lifting equipment on COPI facilities is to be inspected according to the following
schedule:
 6 month interval – Loose lifting accessories and personnel lifting equipment
 12 month interval - lifting appliances such as runway beams and padeyes in
regular use, containers, crane, hoists.
 Prior to use – lifting appliances such as runway beams, pad eyes and special lifting
accessories such as spreader beams/special handling beams and attachments which are
used infrequently, less than once per year
8.4 Inspection Prior to Use
Prior to use, all items of lifting equipment are to be examined by the user to ensure, as far
as it is practicable, that the lifting device to be used is in good condition and it is safe to
be used in accomplishing the task. The user should verify that the lifting equipment has
all of the following:
 Unique identification number
 WLL markings
 Color code that is current (for lifting accessories only)
Should any of the above be missing, the lifting equipment cannot be used and another
piece of lifting equipment that fulfills the above should be used.
For equipment that is fixed, such as a runaway beam, a sign should be affixed in a
manner that is clearly visible to the other potential users that this particular piece of lifting
equipment is faulty and should not be used.
8.5 Proof Load Testing
Lifting equipment will be proof load tested, if required, in accordance with Appendix C –
Lifting Equipment Matrix.
8.6 Inspection
Procedure for conducting lifting equipment certification inspection shall comply with the
United Kingdom Statutory Instrument No 2307 – 1998 The Lifting Operations & Lifting
Equipment Regulations (LOLER),ASME B30 standard and API .
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Further detailed Asset Integrity procedures for loose lifting inspection shall be developed
to meet all Lifting Equipment Certification requirements.
8.7 Synthetic Slings
Polypropylene or nylon polyester slings are the only acceptable alternatives to wire rope
or chain slings and shall be constructed using either of the following methods :-
 Straight strop with a soft-bracketed eye at each end
 Straight strop with metal D-rings at each end.
 Endless round slings

8.8 Wire rope slings

Wire rope slings which are purchased new should be fitted with ferrules so designed that
the tail of the crimped rope is covered by the ferrule but still allows a visual check to be
made on the tail when required at the time of visual inspection of the sling.

8.9 Additional Considerations

Hand made slings are not allowed for ANY lifting at Company Facilities.
Other items that do not fall in the mentioned categories of lifting appliances or
accessories should be identified and marked with a unique number and inspected on a
regular basis.
If a lifting appliance is built by or for COPI for a specific purpose, the appliance shall be
properly engineered and include drawings and calculations to ensure the capacity of the
load supporting elements (i.e. lifting eyes, attachments) is sufficient for its application.
After fabrication, the appliance shall be proof load tested by a competent person who
shall produce a written test certificate.

9 Identification and Records

9.1 7.1 ALL lifting equipment (lifting appliances and lifting accessories) shall be identified with
that identification clearly marked on the equipment including:
 Identification number
 Working Load Limit - All lifting equipment shall have the WLL marked in metric
units (1 tonne = 1,000 kg)
 Color code (for lifting accessories only)

9.2 7.2. The identification shall be stamped into the body of the equipment but in a manner
which does not affect the integrity of the lifting equipment. When this is impractical, the
equipment may be identified with a fixed tag.
9.3 7.3. Lifting accessories shall be color coded to indicate compliance with periodic inspection
and / or re-certification. The color code will be affixed or painted onto the lifting gear.
Each period for color code compliance will last six months. The colors, BLUE, ORANGE,
GREEN and YELLOW will be used in rotation. Lifting appliances (including lifting set for
container / cargo carrying unit) shall not be color coded.
9.4 7.4 In addition to the WLL markings, personnel baskets and personnel lifts shall also be
marked with the maximum capacity in number of persons and maximum weight in
kilograms.
9.5 7.5. A register of the lifting equipment governed by this standard shall be maintained up-to-
date and accessible to every user. This register or inventory should consist of:
 Identification number
 Type of lifting device
 Quantity and serial numbers
 The original test certificate and date of purchase
 Date of last re-inspection / re-certification
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 Proof load test certificate

10 Equipment which has failed Routine Inspection

10.1 Any lifting equipment which appears to be defective as a result of routine inspection by
the user shall be withdrawn from service and quarantined. For equipment that is fixed,
such as a runaway beam which cannot be physically moved to the quarantine area, a
sign shall be affixed in a manner that is clearly visible to the other potential users that this
particular piece of lifting equipment is faulty and should not be used.
10.2 Any defective lifting equipment quarantined (within the quarantine area or out-of-service
as described above) will be subject to specific inspection and testing to determine
whether it is safe for continued operations. The equipment register shall be updated.

Any lifting equipment that physically fails shall be subject to a written failure report. The
specific intent of the failure report is to determine if changes are required to the lifting
equipment inspection procedures. Analysis and testing of a failed component may also
be appropriate.

11 Repair or Modifications to Lifting Equipment

Any item of lifting equipment which has been repaired or modified in any way from its
original configuration should be proof load tested and certified according to this
procedure before it is used.

12 Contractor / Sub Contractor Equipment

Lifting equipment belonging to Contractors and / or their sub-contractors that are used on
Company Facilities shall comply with the intent of this standard. Contractor (s) must use
this standard or demonstrate that they have implemented a lifting equipment safety
program that at least equals the COPI scheme and is to COPI representatives’
satisfaction.
Proof of an effective program by Contractor shall be produced upon demand.
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Appendix A - Referenced Documents

Document No. Document Title
Manpower Minister Regulation No. Per- 01/Men/1989
Qualification and Conditions of Lifting Operator; Decree of
Directorate General Oil and Gas No. 01 K/03/D.DJM/94
Certification Method and Requirements for Crane
Operator; Director General Oil and Gas Decree No.
84.K/38/DJM/1998 Safety Inspection Procedures on
Installation, Equipment and Technique that be used in Oil
and Gas Work.
North Sea Lifting Limited, The International Rigging and
Lifting Handbook, Training Package for Industry.
LOLER (The Lifting Operations & Lifting Equipment
SI 1998 No 2307
Regulations)
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Appendix B – Lifting Equipment List

Specialty items
The following are typical specialty lifting items:
 Cargo containers (containers, metal waste bins, flexible intermediate bulk containers)
 Drum barrel clamps or frames
 Transportable tanks (tote tanks, liquid transport tanks, gas transport tanks)
 Spreader bars
 Cargo nets
 Fall arrest devices
 Personnel lift/work baskets (different from other personnel lifting items such as Frogs)
 Other specialty lifting items (engine lift stands, engine lift bars)
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Appendix C – Lifting Appliances