Lifting & Rigging Operations Safety

Procedure

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 Table of contents
1. INTRODUCTION ....................................................................................................................4

2. PURPOSE..................................................................................................................................4

3. SCOPE .......................................................................................................................................4

4. RESPONSIBILITIES ...............................................................................................................4

5. PROCEDURES .........................................................................................................................6
5.1 LIGHT LIFTING ......................................................................................................................6
5.1.1 General Instructions ......................................................................................................6
5.1.2 Pre-lift Meeting .............................................................................................................7
5.1.3 lift plan ..........................................................................................................................7
5.1.4 CRANE .......................................................................................................................10
5.1.5 Forklift Truck Safety ...................................................................................................13
5.1.6 Lifting appliances ........................................................................................................17
5.2 HEAVY LIFTING SAFETY PROCEDURE : ...................................................................22
5.2.1 General requirements ..................................................................................................22
5.2.2 Drawing and approval .................................................................................................24
5.2.3 Inspection, Certification & Construction ....................................................................24
5.2.4 Load indicator..............................................................................................................25
5.2.5 Access to cranes ..........................................................................................................25
5.2.6 Daily &pre-operational check .....................................................................................25
5.3 CRITICAL LIFT PERMIT.................................................................................................26
5.4 PERSONNEL .........................................................................................................................28
5.4.1 Discipline Engineers/Technicians ...............................................................................28
5.4.2 Safety Officer and Safety/Environment Engineer .......................................................28
5.4.3 Operator .......................................................................................................................28
5.4.4 Signalman ....................................................................................................................28
5.4.5 Riggers.........................................................................................................................29
5.5 CRANE OPERATIONS ...........................................................................................................29
5.5.1 Crane operation precautions ........................................................................................29
5.5.2 Crane Operators...........................................................................................................30
5.5.3 Pre Operating Checks ..................................................................................................30
5.5.4 Operations ...................................................................................................................31
5.6 INSPECTION AND CERTIFICATION GUIDELINES ....................................................................34
5.6.1 General ........................................................................................................................35
5.6.2 Basic Requirements for Inspection Documents ..........................................................36
5.6.3 Basic Requirement for Equipment Marking ...............................................................37
5.7 MAN BASKET SAFETY RULES .............................................................................................37
5.7.1 Basket Loading ............................................................................................................38
5.7.2 Rigging for Man Baskets.............................................................................................38
5.7.3 Inspection of Man Baskets ..........................................................................................38
5.7.4 Trial Lift and Inspection..............................................................................................38
5.7.5 Safety Rules for Men in the Basket.............................................................................39
5.7.6 Safety Rules for the Crane Operator ...........................................................................40
5.8 MOBILE WORKING PLATFORMS ..........................................................................................40

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 5.8.1 Definitions ...................................................................................................................40
5.8.2 Instructions ..................................................................................................................42
5.9 GENERAL SAFETY IN RIGGING AND LIFTING: ......................................................................44
5.9.1 Safe Work Systems......................................................................................................44
5.9.2 Signals .........................................................................................................................44
5.9.3 Rigging a Load with Rigging Equipment....................................................................44
5.9.4 Safety during Crane Operations ..................................................................................45
5.9.5 Preliminary Hazard Analysis.......................................................................................46
5.9.6 Drums and Pulleys.......................................................................................................46
5.9.7 Brakes, Controls, Etc...................................................................................................46
5.9.8 Cranes with Derrick Jibs .............................................................................................46
5.9.9 Location of Cranes and Lifting Appliances ................................................................46
5.9.10 Overhead Power Cables or Pipe-racks.....................................................................46
5.9.11 Stability ....................................................................................................................47
5.9.12 Outriggers.................................................................................................................47
5.9.13 Rigging and De-Rigging of a Crane ........................................................................48
5.9.14 Instruments and Components ...................................................................................48
5.9.15 Crane Markings........................................................................................................48
5.9.16 Qualification and Competency of Lifting Operators & Involved persons...............48
5.9.17 Restriction on Use ....................................................................................................49
5.9.18 Loads ........................................................................................................................49
5.9.19 Security When Not In Use .......................................................................................52
5.9.20 Strong Wind and Rainy Conditions .........................................................................52
5.9.21 Chains, Slings and Lifting Gear. ..............................................................................53
5.9.22 Hooks .......................................................................................................................53
5.9.23 Slings........................................................................................................................53
5.9.24 Tag Lines..................................................................................................................54
5.9.25 Repaired Ropes, Chains, Etc....................................................................................54
5.9.26 Knotted Slings and Chains .......................................................................................54
5.9.27 Unbalanced Load .....................................................................................................54
5.9.28 Shackles ...................................................................................................................54
5.9.29 Eyebolts....................................................................................................................54
6. DEFINITIONS ........................................................................................................................55

7. REFERENCES........................................................................................................................59

8. ATTACHMENTS ...................................................................................................................59

SUGGESTION FORM

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1. INTRODUCTION

Dashti Sanat Company (DSC) aimed at creating superior value and boosting the level of
satisfaction of the beneficiaries and with an approach focusing on sustainable, integrated
and knowledge-oriented production and development, the company feels committed to
comply with national and international requirements, regulations and standards in such
areas as quality, safety, as well as occupational and environmental health.

2. Purpose
To outline the requirements for managing and controlling lifting and rigging operations
during activities DSC projects.
It is the purpose of this document to provide guidance during the assessment of each
equipment lifting operation, and to aid him in the safe execution of his contract
obligations.

3. Scope
This procedure applies to all operations involving the use of Cranes, Lifting Gear, Hoists,
Fork Lifts and Telescopic Material Handlers. For lifts that are programmed to go over live
process areas, in the vicinity of other potentially hazardous areas and passing overhead or
nearby members of the public, these requirements need to be reviewed, assessed and planned
for applicability.

4. RESPONSIBILITIES

4.1 Site Manager

To ensure that all lifting operations are adequately planned and executed and that all
lifting equipment used on site is certified and conforms to this procedure.

4.2 HSE Manager

 To liaise with all members of the Project Management Team, Supervisors and contractors
on the planning of all lifting including erection, certification and maintenance of all
lifting appliances as per item 3 (scope).
 To ensure that all persons involved in the lifting operations are competent and
suitably trained in HSE matters for the operations to be performed.
 To ensure that all lifting appliances and gears are properly tested and certified, fit for
their intend purpose and are maintained and inspected at appropriate intervals.

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4.3 Contractor(s)
In cases that a main HSE contractor exsist, duty of HSE department forwarded to
contractor HSE department and DSC HSE department supervise them. Some of
their duties are:
 Contractor shall bring to the attention any item of equipment which is in need of
maintenance, or which is found to be overdue for test or inspection.
 To ensure that all persons involved in the lifting operations are competent and suitably
trained in HSE matters for the operations to be performed.
 To ensure that all lifting appliances and gears are properly tested and certified, fit for them
intend purpose and are maintained and inspected at appropriate intervals.

4.4 Lifting Supervisor

 To ensure that the crane operation team carry out their duties safely.
 To carry out the assessment of the lifting operation to provide such planning, selection
of crane(s), lifting gears and equipment, instruction and supervision as necessary for the task
to be undertaken safely.
 To ensure that adequate inspection and maintenance of the equipment has been carried
out.

4.5 Discipline Engineers/Technicians

All Discipline Engineers/Technicians are required to ensure that all operations using
light lifting gear are performed in accordance with this Procedure.

4.6 Safety Officer and Safety/Environment Engineer

The Safety Officer and Safety/Environment Engineer are responsible for monitoring
safe working practices on site.

4.7 Senior Inspection Engineer

The Senior Inspection Engineer is responsible for ensuring that all lifting gear is
examined and tested in accordance with this Procedure.

4.8 Lifting Operators

 To be responsible for the correct operation of the crane in accordance with the
manufacturer's instructions and within the Safe System of the work.
 To respond to the signals from the banksman who should be clearly identified at any time.
 To ensure the crane is in good working condition by daily inspection.
 To be familiar with the fire appliance on the crane and trained in their use.

4.9 Riggers
 To be responsible for attaching and detaching the load to and from the crane load lifting attachment
and for the use of the correct lifting gear and equipment in accordance with the planning of the
operation.
 To ensure that adequate inspection and maintenance of the equipment has been carried out

4.10 Banksmen

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  To be responsible for relaying the signal to the crane operator.
 To direct movement of the crane and load.

5. Procedures
5.1 Light Lifting
The incorrect use of light lifting equipment can be hazardous. This is because light lifting equipment is
sometimes not subjected to the same rigorous inspection schedules as heavier lifting equipment such as
cranes, etc . However the same basic principles must apply :

 The SWL of the equipment should always be known.

 All light lifting gear must be thoroughly examined and tested.
 All tests and examinations must be properly documented. All documents shall be
maintained and quickly accessible for internal or external auditing by company, contractor or
third party.
 All equipment should have the appropriate colour coding.
 Only trained and competent persons should be in charge of a lifting operation.

5.1.1 General Instructions

All equipment used in light lifting operations whether fixed or portable must be inspected and/or tested
to confirm that it is fit for its intended use. A color coding system is used to ensure that all equipment
in use has been either inspected or tested. The color code is changed every three months. No
equipment other than those bearing the valid color displayed is allowed to be used in lifting operations
Every lifting appliance or piece of lifting gear must be clearly marked with its working load or loads
and must be used within these parameters.

 If No Safe Working Load, Identification Number or the correct Color Code adequately
marked, then DO NOT USE IT.
Lifting appliances and associated lifting gear must be examined and where necessary
tested by an approved inspector as follows :
 Before it is used initially.
 Whenever the equipment has been substantially modified or repaired and before it
is used again.
 At intervals and times laid down by TPA and/or in accordance with the relevant
legislation.
 Color coding system shall apply for all machines & equipments in site such cranes, lift
trucks, forklifts, chains, slings, shackles, …by contractor HSE. (Every three month).
 Particular, daily, weekly, monthly and pre use inspections for lifting devices &
equipment should be done and approved by a certified third party in compromised
specific periods.
 Of course above mention system is so different for wire rope and critical lifting.
 PM (Preventive Maintenance) as a essential system should be deployed at the whole
system.
 All examinations and tests must be recorded in a lifting equipment register
(attachment 3). A current copy of the register must be available on the site. All lifting
gear is to have an identification number clearly marked.

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  Any appliance or piece of lifting gear that fails the examination or test must not be used
until it is repaired and retested.
 Any lifting gear which fails during an operation must not be moved until an investigation
has been carried out. This does not apply in emergency situations.

5.1.2 Pre-lift Meeting

Staff should participate in the meeting hold which is called Pre-lift Meeting to review the
plan/procedure before making a critical or pre-engineered lift. All participants should be briefed as
follows (and as a minimum):
 Intended lift sequence and load path;
 Establishing a Work Control Zone and keeping no participants out;
 Identified hazards;
 Methods of hazard mitigation;
 Load securement;
 Stop Work Authority

5.1.3 Lift plan

Regulations :
A lift plan should be prepared prior to lifting tilt-up or pre-cast panels. The plan should show a
dimensioned site plan with the following information detailed:
 crane set-up position(s) on site;
 locations where the panels are to be lifted from and to, with the operating radius of the crane
shown;
 areas on site where obstacles such as walls or braces may be in the traveling or slew path of
the crane; and
 Areas where the crane cannot be set up (i.e. trenches and covered penetrations on site).

 The lift plan should specify the type and set up of lifting gear to be used.
 Responsibilities for rigging, dogging and spotting duties (i.e. ensuring the crane does
not contact obstacles) should be specified.

5.1.3.1 General : Purpose

This section describes the process of how to use the hoisting and rigging lift plan (HRLP) and
conduct safe hoisting & rigging activities

Scope
The introduction of the hoisting and rigging lift plan document. This Lift Plan can be used to perform
all routine hoisting & rigging activities and will still be completed for non-routine and hoisting and
rigging activities requiring special lift fixtures and processes.

Recordkeeping

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This procedure requires the preparation and approval of a Lift Plan for each lifting activity. Lift
Plans have unique document numbers. Copies of approved lift plans must remain on file with the
area supervisor during the job in progress and later added to the engineering document archive.

Applicability
This procedure applies to all routine hoisting & rigging activities performed by personnel.

Precautions and Limitations

Ensure that below-the hook lifting devices; and cranes, hoists, and other lifting equipment are
never loaded beyond their rated capacity.

Equipment Description
The types of lifting equipment covered by this procedure include:
Overhead cranes: common names used to describe these include bridge, gantry, mobile gantry,
monorail, jib, floor-operated, and wall mounted cranes. Shop cranes, engine hoists, and cherry
pickers. Forklifts - when used with rigging gear.

5.1.3.2 Operator qualifications and requirements Training

Personnel who operate cranes and hoists must be current in Hoisting & Rigging training.

5.1.3.3 Job Hazard Analysis and Mitigation (JHAM)

Personnel who are involved in hoisting & rigging activities must have hazard analysis
documentation (routine or non-routine JHAM) that addresses hoisting & rigging activities. Many
elements of the JHAM process (hazard identification and mitigation) are included in this procedure,
and do not need to be repeated in a JHAM

5.1.3.4 Preparing a Lift Plan

This procedure requires that a Lift Plan be prepared and approved for all routine hoisting & rigging
activities. A Lift Plan provides a formal mechanism to plan, document, and perform hoisting &
rigging activities. Lift plans can be re-used for identical tasks. Lift plans must be prepared using
the Hoisting and Rigging Lift Plan template.

General Information
The following general information should be included in the Lift Plan:
Unique document number, Author of lift plan, a general description of the load and the lift
activity.
Indication of radioactivity or hazardous materials that could be released if the load were dropped.
Indication if the load is irreplaceable or very costly to replace if damaged.

Equipment Information
Equipment ID (hoist #, forklift #, Building crane#) and custodian.
Rated capacity and operator capacity if applicable different from rated capacity.

Personnel Protective Equipment (PPE)

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The plan must identify the potential hazards to personnel, and the personnel protective
equipment required to mitigate those hazards.

Hazards
Identify additional hazards associated with the lift and describe how they will be mitigated.
Examples of hazards/mitigations to consider include:
 Obstacles in the operator or load path (walk load path and remove obstacles prior to
lift).
 Foot traffic around load (barricade work zone).
 Special hazards or precautions of rigging equipment.

Rigging sketch
The rigging sketch is a critical element of the lift plan. It diagrams all of the rigging details
for the activity. All rigging gear used in the lift must be sufficiently rated to withstand the forces that
will be applied to it during the lift. The rigging sketch must contain enough information to
demonstrate this.

Note: If the physical characteristics (size, weight, or configuration) of the item changes significantly
during the manufacturing process, or if you will be handling the item is various positions, a rigging
sketch may be required for each configuration.
Approvals and Authorization
Lift plans must be “approved” for use as described below. Once a lift plan has been approved,
specific personnel are “authorized” to use the plan

5.1.4 CRANE
All contractors of crane and heavy construction equipment shall be subject to inspection by
a Competent Person (HSE Department Rigging Inspector or its nominated representative) prior
to entry to the Work Site and shall enter the Work Site through contractor controlled main gate.

HSE Department shall maintain records of all mobile cranes entering the Work Site using valid Road
Transport Department (RTD) registration numbers.
Cranes requiring assembly at the Work Site shall be load tested in accordance with construction
industry requirements and the manufacturer's recommendations.

HSE Department shall :

 Direct the mobile crane or equipment to the holding area adjacent to the main gate.
 Check for records of any crane Work. Site history, if any, so that any cranes that have
been rejected or disallowed earlier from Work Site are screened.
 The Crane / Motor Vehicle Inspection Checklist' as in Attachment #2 of this Procedure,
shall be completed.
 Restrict any crane disallowed by HSE Department, its nominated representative or
Company from entering Work Site.
 Provide the approved cranes with a entry pass.
 Ensure that cranes are inspected on every occasion they re-enter Work Site.

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  HSE Department or its nominated representative shall verify that Crane Load Charts
are available in the crane cab, are written in the English language and/ or Farsi, and that the
crane operator understands their content.
 HSE Department shall verify all third party inspection certification regarding cranes, lifting
appliances and equipment prior to the use of the crane or equipment at the Work Site.(if third
party inspectors will be requested)

Contractor shall ensure that :

 Only cranes and rigging equipment (slings, wire ropes, shackles etc.) suitable for the job
intended and maintained in good working order are brought into Work Site.
 HSE Department are notified of the arrival of any crane and/ or rigging equipment, to be
utilized by the contractor, to Work Site to enable crane records to be reviewed, if applicable,
and to arrange for the crane inspection by a competent person.
 All lifting and rigging equipment either owned by the contractor, or by others
employed by the contractor, is. Registered using the "Lifting Equipment Register" as per
Attachment #3 of this Procedure.
 Lifting and rigging equipment must be inspected by the nominated Competent Person prior
to being brought into and used at the Work Site and monthly thereafter.
 Following the initial inspection the equipment shall be color coded every three month
 Period as per color coding instructions that will be issued by HSE Manager.
 The nominated Competent Person or their authorized representative shall inspect all crane
wires and slings upon entry to Work Site and then based on this procedure thereafter.
Inspection details shall be recorded in the "Wire Rope Inspection" form as per Attachment
#3 of this Procedure.
 Following the above inspection every wire rope, belt slings, chains, etc. must be
clearly marked with its Safe Working Load and carry a metal identity tag and be color coded
accordingly.
 Hand spliced wire ropes shall not be brought into the Work Site.
 The nominated Competent Person shall submit to HSE Manager all entries made in the
"Lifting Equipment Register" and "Wire Rope Inspection" forms after each three- monthly
inspection.

5.1.4.1 Crane Preventive Maintenance Programs

Preventive maintenance programs would customize that reduce down time so we can get the
optimum use out of our lifting equipment. A maintenance program would be created to help avoid
costly emergency repairs and down time. This program would be developed based on needs,
industries standards, and OSHA recommendations.

A comprehensive inspection combined with a custom PM program will identify trouble spots
before they become a problem. The PM program will include the following:
 Inspections of all wear items for signs of excessive wear or fatigue
 Load chains or wire ropes
 All components requiring lubrication

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  Checking gear-boxes for proper levels
 Checking control stations for safe operation
 Inspect all structure and support for safe operation
 Test brakes for proper operation and adjust as needed
 Confirm all limit switches and safety devices
 Inspect all contactors and replace tips as needed
 Inspect and lube load hooks and other lifting devices
Notice: it's unavoidable that PM team is in charge of all above mentioned duties

5.1.4.2 Crane maintenance

What should be checked for inspecting a crane before maintenance?

 Lower hoist to unload rope sheaves.
 Unwind all wire rope from the hoist drum to expose all parts of a rope, making sure that
the rope does not rewind in the reverse direction.
 Inspect sheaves, sockets, dead-ends, thimble joints, and all wire rope hardware.
 During rope changes, check the sheaves for worn bearings, broken flanges, proper groove
size, smoothness, and contour.
 Inspect all parts of the cable, cleaning wire rope only as required to complete an inspection.
Excessive removal of lubrication will lead to damage.
 Re-lubricate rope to prevent corrosion, wear, friction, and drying out of the core.
 Check for ropes that may have been operated dry (UN lubricated). Replace dry ropes.
There may be hidden damage that is not detected by visual inspection.
 Compare the rope length and diameter with the original dimensions. Lengthening
accompanied by diameter reduction is often an indication of interior core defects.
 Visually examine the crane structure for deformed, cracked or corroded members in the
structure and boom.
 Check for loose bolts or rivets. Check for excessive wear on brake and clutch system
parts.
 Check for deterioration or leakage in air or hydraulic systems.
 Check all control mechanisms for poor adjustment or excessive wear.
 Check accuracy of marking on the load/radius indicator over full range.
 Establish a schedule of rope replacement to change wire rope before it breaks.
 Periodic replacements do not take the place of inspections. If rope breaks or inspections reveal
abnormal wire breakage or defects, reduce the time between replacements.
 Do not make wire rope slings from used wire rope.

What are some things to remember when repairing a crane?

 Take a crane to a location where repairs will least interfere with other cranes.
 Ensure that all controllers are placed in the "off" position, and the main switches are open
and locked.
 Place on the switch a standard warning tag stating "DO NOT START." The tag must be
filled out and signed

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  Place rail stops or make other safety provisions when another crane operates on the same
runway.
 Use fall protection equipment.
 Do not carry anything in your hands when going up and down ladders. Items that are too
large to go into pockets or belts should be lifted to or lowered from the crane by a rope.
 Prevent loose parts or tools from falling to the floor.
 The area below the crane must be cleared and a barrier erected to prevent injury from a
falling object.
 Replace all guards and other safety devices before leaving a crane.
 Remove all stops, tools, loose parts and other material and dispose of them before
completing the repair job.
 Enter all service inspections and repairs in a crane log book or file.

5.1.5 Forklift Truck Safety

Industrial workplaces have come to rely on forklift trucks for their ability to lift and transport just
about any load around the plant. The power of forklifts makes them indispensable, but also
dangerous. Often when employees grow accustomed to using forklifts they tend to stop thinking of
them as a safety hazard, and forget or neglect to follow some important operating and maintenance
procedures. When forklift injuries occur, they're usually serious given the tremendous weight
of those powerful machines.

Employees must be trained to work safely with forklifts, not just when they're hired but periodically
thereafter. Refresher training for the experienced operator is just as important as first-time training
for new employees. It's also a good idea for employees to receive basic first aid training in case of
injuries.

5.1.5.1 Forklift Inspection

Although forklifts are designed to perform rugged tasks, each time they are used they can get
damaged in any number of ways. That's why inspection is of critical importance. At the start
of each shift, perform both a visual inspection of the general condition and cleanliness of the lift
truck, as well as an operational check to test its proper functioning. If you notice anything that may
affect the normal operation of the forklift, immediately alert your supervisor.

Checklist for Visual Inspection

 floor--clear of objects that could cause an accident
 no obstructions overhead
 note any nearby objects to avoid as you drive away
 fire extinguisher present, and charged
 engine oil level, fuel level, radiator water level (LPG, gas and diesel forklifts)
 battery fully charged and securely in place
 cables for exposed wires
 battery plug connections not loose, worn or dirty
 vent caps not clogged
 electrolyte levels in cells
 hold downs or brackets
 bolts, nuts, guards, chains, or hydraulic hose reels not damaged, missing or loose

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  wheels and tires not worn or damaged
 air pressure of pneumatic tires
 forks not bent or cracked
 positioning latches in good working condition
 carriage teeth not broken, chipped or worn
 chain anchor pins not worn, loose or bent
 no damp spots or drips that may indicate a leak
 hoses held securely, not loose, crimped, worn or rubbing
Checklist for Operational Pre-Use Inspection
 horn working and loud enough to be heard in working environment; other warning devices
operational
 floor brake: pedal holds, unit stops smoothly
 parking brake: holds against slight acceleration
 dead man seat brake: holds when operator rises from seat
 clutch and gearshift: shifts smoothly with no jumping or jerking
 dash control panel: all lights and gauges operational
 steering: moves smoothly
 lift mechanism: operates smoothly (check by raising forks to maximum height then
lowering completely)
 tilt mechanism: moves smoothly, holds (check by tilting mast all the way forward and
backward)
 cylinders and hoses: not leaking after above checks no
unusual sounds
 Permit only qualified people to service and maintain forklift trucks.

5.1.5.2 Forklift Operation

No one must ride or operate a forklift truck except for a trained forklift operator who is able to
maintain control of the forklift and operate it smoothly when stopping, starting, lifting and tilting.
The following pages list some important guidelines on forklift safety.

Traveling

Keep your hands, arms, head, feet and legs inside the forklift truck. Travel with forks as low as
possible from the floor and tilted back. Obey posted traffic signs. Decrease speed at all corners,
sound horn and watch the swing of both the rear of the lift truck and the load. Avoid sudden stops.
If the load blocks your vision, travel slowly in reverse. Always look in the direction of travel. Keep
an eye out for oil spots, wet spots, loose objects, holes, rough surfaces, people and vehicles on the
floor or roadway.
To ensure the safety of others, know the blind spots of the lift truck with and without a load. When
anyone crosses the route being traveled, stop the forklift truck. Lower the load to the floor, and wait
until passage is clear.

Traveling on an Incline

Keep the forks pointed downhill without a load, and pointed uphill with a load. Do not attempt to
turn the lift truck until it's on level ground.

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Steering

Support the load by the front wheels and turn with the rear wheels. Do not turn the steering wheel
sharply when traveling fast. If the lift truck is overloaded, steering will be difficult. Do not exceed
load limits, and do not add a counterweight as an attempt to improve steering.

Loading

It's important to know the recommended load limit of the forklift (shown on the data plate) and the
capacity of the fork, and to never exceed these limits.

Position the load according to the recommended load centre. Do not add extra weight to
counterbalance an overload. Keep the load close to the front wheels to keep the lift truck stable.

When inserting the fork, keep the mast of the forklift in an upright position before inserting the fork
into a pallet. Level the fork before inserting it.

Raising the Load

Do not raise or lower the fork unless the lift truck is stopped and braked. Avoid lifting a load that
extends above the load backrest if there's any risk of the load, or part of it, sliding back toward the
operator. Check for adequate overhead clearance before raising a load, and maintain a safe
working distance from overhead power lines. Lift the load straight up, then tilt back slightly.
Watch that the load doesn't catch on adjacent loads or obstructions. Don't back up until the forks
are free.

When a load is raised, the lift truck is less stable. The operator must stay on the forklift when the
load is in a raised position. Don't allow anyone to stand or walk under the elevated part of the forklift,
whether it's loaded or unloaded.

Handling Pallets
Ensure that forks are level and high enough to go into the pallet, and that they go all the way
under the load. Forks must be the proper width to provide even weight distribution.

Avoid trying to move or adjust any part of the load, the forklift or the surroundings when on the
forklift. Do not use pallets elevated by forklifts as an improvised working platform.

Parking

Park only in an approved location. When leaving the lift truck unattended, secure it by setting the
brakes, lowering the forks or load to the floor, neutralizing the controls, and turning off the motor
switch. Disconnect the battery or go through propane shut-down procedures.

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Loading or Unloading Straight Trucks, Tractor Trailers, and Railway Cars
Preparing the vehicle being loaded or unloaded
Set the vehicle's brakes, and chock the wheels. Install fixed jacks to support a semi- trailer that is
not coupled to a tractor to prevent it from upending. Post signs warning people not to move a
vehicle. Check that the height of the vehicle's entrance door clears the forklift height by at least
5 cm (2 in). Make sure floors can support the combined weight of the forklift and the load.

 Inspect the vehicle's interior for trash, loose objects and obstructions, holes in the floor,
and poor lighting. Install no slip material in any area that could be a slipping hazard.

 Ensure that docks and dock plates are clear of obstructions and not oily or wet. Loading or unloading
the vehicle
 Stay clear of edges of docks, rail cars or ramps. Have edges clearly marked.

 Do not tow or push railway cars or trucks with a forklift.

 Do not operate forklifts inside vehicles for long periods without ventilation.
 Make sure that the dock plate is properly secured and can support the load (load weight
should be clearly marked).
 Drive carefully and slowly over the plate. Do not spin the wheels.

Loading railway cars

Cross the railway track on a diagonal. Set handbrakes, wheel blocks and derailed before
entering a railway car. Do not park a forklift within three meters of railway tracks. Do not open
railway car doors with forklift forks.

Entering an Elevator with a Forklift Truck

Do not enter any elevator unless specifically authorized to do so. Before entering, ensure that the
forklift plus load weight does not the exceed the elevator capacity. Approach the elevator slowly.
Stop at a safe distance from the elevator gate, and then enter squarely.

Neutralize the forklift controls. Shut off the motor and apply the brakes.

When working on or near a forklift, stay alert and prepare for the unexpected.
Immediately report any collisions, damage or near-misses to a supervisor.

5.1.6 Lifting appliances

5.1.6.1 Wire Ropes

These are normally small electrically powered winch-drums arranged for overhead
suspension, often on a traveling carriage. The following conditions apply:
Wire ropes are used on cranes, hoists, hangers and etc. including passenger transfers. The following
precautions (including Coding system, Colour coding, Identifying & Tracing system like Labeling
and …) must be taken simultaneously when handling or fitting wire ropes:
 Always wear protective gloves, do not wear rings.
 Avoid twisting or kinking wire ropes.
 Ropes in use must be lubricated periodically.

15
  Check that the rope is of the correct specification for the crane to which it is to be fitted.
 Ropes must be fitted to the relevant equipment in accordance with the instructions of the
equipment manufacturer.
 Ensure all anchorages are secure and only the correct fittings are used.
 Rope guards must only be removed for the purpose of maintenance, inspection or
adjustment.
 All slings and strops shall be examined by the user before and after each use.
 Ropes must be discarded when the visible number of broken wires in any length equal to
ten times the rope diameter exceeds 5% of the total number of wires in the rope.
 Ropes removed from equipment as unserviceable must be identified as such, brought
to the attention of the Site Manager and removed from the register.
 When a rope is replaced the test certificate of the new rope must be retained with the
register of the lifting equipment.
 Replacement rope must be stored on pallets or drums in a place where deterioration from
condensation is minimized.
 The supporting beam must be properly designed by a competent person.
 The Identification number and Safe Working Load (SWL) must be recorded on the
blocks.Only the correct wire rope, in accordance with the manufacturers’ instructions,
should be used.
 The wire rope must be installed and laid on the drum smoothly and under tension.
 If the wire rope becomes crossed on the drum it is to be immediately paid off and re-laid.
 The wire rope and block shall be inspected weekly and a record kept.
 Notice : The form (attachment # 3) could be used for this purpose .
 The operator shall be trained in the use of powered wire rope lifting blocks

5.1.6.2 Chain Hoist

Before use ensure that the load to be lifted does not exceed the safe working load marked on the
hoist, and that the support points for the hoist are capable of taking the load.
Additional precautions to be taken during the operation of the hoist are:
 The chain should never be run out to its full length so that the load is hanging on the
chain retaining bolt.
 The load chain must not be used to encircle the load; slings must be used.
 Loads must not be left suspended and unattended on a chain fall without first
securing the pull chain.

5.1.6.3 Shackles
The procedure for lifting shackles is as follows:

 Use the correct type of shackle for the job in hand.

 Check the safe working load (SWL) and color code of the shackle.
 Do not use any shackle which is not marked with the SWL.
 Do not use any shackle which shows damage or distortion.
 Always use the correct shackle pin.
 Make sure the pin is a good, secure fit in the shackle.

16
  Never side load a shackle, the hook should always be in the bow, above the pin.
 Do not use shackles which have been subjected to welding operations.
 Do not use shackles which have been heated to widen the jaws.

5.1.6.4 Eye Bolts

The procedure for the use of eye bolts is as follows:

 Check the safe working load (SWL) and color code of the eye bolt.
 The SWL refers to vertical lifts and is reduced by an inclined lift.
 Check that thread of the eye bolt is the same as the tapped hole and make sure the thread
is a good fit.
 Ensure that the shoulder or collar is in contact with the load.
 Use a collar eye bolt for inclined loading. On an inclined lift the eye must always be in
line with the sling.
 When using welded pad eyes on structures, ensure the weld has been load tested.
 When using a single eye bolt lift, prevent the load from rotating by the use of a tag line.
 No single point lifts should be made over a deck area.

5.1.6.5 Chains

Chains are not normally used as a lifting device except for barrel lifting slings. All such must be
checked before use. The procedure to be followed is:

 Check the safe working load (SWL) and color code before using.
 Do not use a chain which is kinked or twisted.
 Never hammer a chain down on to a load.
 Do not use a chain which is pitted or corroded.
 Never lengthen a chain by joining pieces together.
 Never shorten a chain by knotting.
 Do not drop chains on hard surfaces.
 Always use suitable packing to protect chains from sharp corners.

5.1.6.6 Pulley Blocks with Fibre Ropes

 The reeving of multiple fall blocks using fiber ropes is an accepted part of a trained
rigger's role. The following conditions apply:
 The SWL is not normally marked on fibre ropes. Information should be available on site
concerning the SWL relating to various sizes and types of fibre ropes. Fibre rope terminations
should be performed by a skilled person. Any knots should be frequently checked.
 Anchor points should be checked by an Inspection Engineer in advance.
 Due allowance should be made for impact / snatch loads.
 Hooks used on fibre ropes or on fibre rope return blocks should be fitted with a safety
catch. Bent pieces of wire are not acceptable. Hooks should be properly spliced onto rope.

5.1.6.7 Slinging and Lifting (Figures 1, 2, 3, 4 & 5)

17
Tables of safe working loads shall be available for all lifting gear and be retained by the relevant
superintendent with the Lifting Appliance Registers. These must be consulted to enable the correct
size of lifting gear to be selected.

When using multiple leg slings the safe working load decreases as the angle between the legs
increases. For three and four leg slings the safe working load is determined by the largest angle
between the legs. Special care must be exercised, Practiced and calculated when a larger size sling
is supposed to be used in following cases:

 The exact load is in doubt.

 There is liable to be shock loading e.g. lifting from / to a vessel.
 There are exceptional hazards, or the possibilities of accidents are seen to exist
(e.g. lifting over "live" plant).
 when passing over sharp or machined edges of equipment.
 When using a single sling to lift pipes or equipment with no lifting eyes or hoses, the sling
must be wrapped around the equipment with at least two turns.
 Hook points must always point outwards when using multiple leg slings.

The following list of prohibited actions is brought to the attention of all personnel using lifting
gear:
 Never lift with the point of a hook.
 Never use nuts and bolts to join a broken chain.
 Never use a chain in which the links are locked, stretched or are without free movement.
 Never use corroded, worn or excessively pitted chains.
 Never hammer a chain to straighten a link or to force a link into position.
 Never drag a sling from under a load if it is not free.
 Never cross, twist, kink or knot any sling.
 Never drop any item of lifting gear from a height.
 Never join slings by threading the eyes.
 Never attempt to force a spread hook back into shape.

5.1.6.8 Pre-Slinging of Pipe work, Containers, Etc.

Load (sets) must be properly assembled, slung and have tag lines attached before t hey are hoisted
or lowered. Before heavy loads, such as long lengths of rolled sections, tubes, etc., are swung, the
load must be given a trial lift to test the security of the slinging.
Strops and slings must be so applied and pulled sufficiently tight to prevent the load, or any part
of the load, from slipping and falling.

Lifting hooks must not be attached to:

 The bands, strops or other fastenings of packages of cargo, unless the fastenings have
been provided for lifting purposes.

18
  The rims (chins) of barrels or drums for lifting purposes, unless the construction
and condition of the barrels or drum is such as to permit lifting to be done safely with
properly designed and constructed can hooks.
 Suitable precautions, such as the use of packing or chafing pieces, must be taken to prevent
chains, wire and fiber ropes from being damaged by any sharp edges of loads.
 The angle between the legs of slings should not normally exceed 90º Where this is not
reasonably practicable, the angle may be extended up to 120º, provided that the slings are
designed to work at the greater angles and have an appropriately greater safe working load
rating.
 Trays and pallets must be hoisted with four-legged slings and, where necessary,
precautions, such as the provision of nets, must be taken to prevent any part of the load from
falling.
 When bundles of long metal goods such as tubes, pipes and casing are being hoisted,
two slings double wrapped and bulldogged, and where necessary, a spreader must be used.
Suitable tag lines should also be attached. Buckets, skips and similar appliances must be:
 So loaded that there is no risk of the contents falling out, by using retaining nets where
necessary.
 Securely attached to the hoist (e.g. by a shackle) to prevent tipping and displacement.

 Shackles should be used for slinging thick sheet metal, if there are suitable holes in the
material, otherwise suitable clamps on an endless sling must be used.
 Small drums, canisters, bottled gases, etc., must be loaded or discharged in suitable
containers or skips with sufficiently high sides, lifted by four-legged slings.

BS 1290 states the following:

(a) 2 - Leg Sling

With a 2-leg sling, the SWL of the sling is not doubled but the SWL of one sling * 1.4
(up to an angle of 90º). For an angle above 90º the SWL of the pair of slings is the
same as for one sling only.

(b) 3 - Leg Sling

The legs should be equally spaced and equally loaded. The angle between any two
adjacent legs should not exceed 90º. Up to this angle the SWL will then be the same as
for a single sling * 2.1.

(c) 4 - Leg Sling

It is difficult to arrange for equal tension in the legs. Therefore the SWL is the same as
a 3-leg sling. The angle is measured between two diagonally opposite legs.

All multiple slings should be marked with a SWL and a maximum internal angle. For
example, a 2 leg sling marked "SWL - 5 Tones 90º " can be used for lifting 5 tones
with a maximum angle between the slings of 90º.
5.1.6.9 Slinging Procedures

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The procedure for slinging operations is as follows:
 Know the weight being lifted.
 Check the safe working load (SWL) and color code of the sling.
 Select slings long enough to avoid a wide angle between the legs of a multi-leg sling.
 Ensure all legs of a multi-leg sling are evenly loaded.
 Never shorten chains or wire slings by tying knots or wrapping around the crane hook.
 Insert suitable packing to protect slings from any sharp corners, particularly when lifting
steel sheets.
 Use end links, rings and shackles which are large enough to hang freely on the crane
hook.
 To prevent swinging when the load is lifted, ensure that the hook is placed above the
centre of gravity of the load.
 When slinging casing, fit bulldog grips to retain the sling in position when the load is
lowered.
 With a multi-fall hook use a safety pennant on to which the load is hooked.
 If two slings are to be joined, shackles of compatible safe working load must be used.

5.1.6.10 Lifting Steel Plates Edgewise (SEE FIG 6)

1. The safest way of lifting steel plates is with holes near the edge to attach the lifting
slings via shackles.
2. For plates without holes, plate clamps must be used. These clamps, which depend
on friction gripping, are not as positive as shackles. The greatest care must therefore be
taken. When employing a single clamp it must be attached squarely to the plate.
Packing must never be used between the clamp and the plate. A single clamp must not
be used to lift more than one plate at a time.
3. Plate clamps are to be marked with a SWL, Identification number and be color
coded.
4. Where a crane hook is attached directly to a clamp or shackle, over lowering of the
crane hook is liable to detach the hook from the shackle and the plate can then fall
over. This risk is greatly reduced by having a short wire sling between the clamp or
shackle and the crane hook. When using two lifting clamps on a plate, each clamp
must be in line with the leg of the sling attached to it.
5.2 HEAVY LIFTING SAFETY PROCEDURE :

5.2.1 General requirements

All requirements of light lifting is applicable for this section also.
For the purposes of assessing the handling equipment required, the weight of the individual
components identified as being capable of being handled as a unit, have been considered. Each
identifiable component should be listed with its corresponding unit weight and the model of
construction crane suitable for the operation. This document shall be reviewed and revised during
construction upon changes in machinery or equipment dimensions and weights or when any
changes are met in the attached classification listing.
The manufacturer’s specifications and limitations applicable to the operation of any
and all cranes and derricks shall be complied with their specifications.
20
Rated load capacities, recommended operating speeds, special hazard warnings, or instructions must
be visible to the operator while he is at the control station.
All lifting and rigging equipment such as cranes, slings, ‘D’ shackles, hooks, etc. shall be certified
by HSE at least for 6 months and all relevant certificates shall be copied to the HSE department.

Rigging equipment must be inspected by HSE every 3 months, also operator should check the
equipments prior to use on each lifting operation and as necessary during its use to ensure that it is
safe.
Defective rigging equipment must be tagged out of service and removed from the site. Contractor
lifting supervisor and HSE Manager shall make a thorough, monthly inspection of the
hoisting machinery. The operator shall maintain a record of the dates and results of inspections for
each hoisting machine and piece of equipment.

Standard operating signals should be agreed upon and should be used to direct all operations.
No modifications or additions, which affect the capacity or safe operation of the equipment, shall be
made without the manufacturer’s written approval.

Accessible areas within the swing radius of the rear of the rotating superstructure of the crane
must be barricaded to prevent any personnel from being struck or crushed by the crane.
All cranes and lifting appliances shall be plainly marked on each side of the appliance as to its rated
load capacity.

The following restrictions during lifting operations shall be observed:

 Personnel shall not ride on the hook or load.
 Personnel shall not stand, walk or crawl beneath a slung load.
 The hoist rope shall be in a vertical position when tensioned to prevent swinging of the
load.
 The twisting or kinking of the wire rope shall be avoided.
 Bolts and nuts shall not be used to join a broken chain.
 Lifting appliances shall not be dropped from a height.
 Tension shall not be applied to any kinked wire rope.
 No heavy lifting operations shall proceed until a detailed lifting plan has been prepared by
mechanical department and approved by the HSE. A Heavy Lift shall be categorized
as that in which the load exceeds 20 tons.
 If no Safe Working Load (SWL), Identification Number or correct Color Code is adequately
marked, then do not use.
 Every lifting appliance or piece of lifting gear must be clearly marked with the SWL
 and must be used within these parameters.
Lifting appliances and associated lifting gear must be examined and where necessary tested by HSE
inspector as follows:

Before it is used initially.

 Whenever the equipment has been substantially modified or repaired and before it is used
again.

21
  At intervals and times according to Inspection Procedures and/or in accordance with
the relevant legislation.
 All examinations and tests must be recorded in a lifting equipment register. A current copy
of the register must be available on the site. All lifting gear is to have an identification number
clearly marked.
 Any appliance or piece of lifting gear that fails the examination or test must not be used
until it is repaired and re-tested.
 Any lifting gear that fails during an operation must not be moved until an investigation has
been carried out. This does not apply in emergency situations.

5.2.2 Drawing and approval

All heavy lifting should be planned by Mechanical department and receive approval from HSE
department. Mechanical section prepares the lifting plan contains all equipments technical details
(crane, lifting equipments ) and the location, the load characteristics such as weight, dimensions and
so, all necessary precautions, the responsible persons and the time. HSE receives this permit after
signs by mechanical heavy lifting responsible and they start to review the documents and make a
risk assessment. If HSE founds some more precautions or any special item, they inform to
mechanical department to follow. The operations should be done after approving the permit by HSE.
5.2.3 Inspection, Certification & Construction

All equipment used in lifting operations whether fixed or portable must be inspected and/or tested
to confirm that it is fit for its intended use. A color coding system is used to ensure that all equipment
in use has been either inspected or tested. The color code is changed every 3 months. No equipment
other than those bearing the valid color displayed is allowed to be used in lifting operations.

A certificate shall be issued for all cranes by HSE Lifting and Rigging section. Entrances and
Operation of any crane shall not be permitted before receiving suitable certificate from HSE
department.
All cranes should be inspected, as a minimum, in accordance with the local legislation. The
inspection should be carried out by HSE Lifting and Rigging section in accordance with
national and international rules.

Every lifting appliance, and all parts of it, shall be,

 Of good construction,
 Of sound material,
 Of adequate strength,
 Free from patent defect,
 Suitable for purpose for which it is used,
 Adequately & securely supported.

A proper working place and proper means of access for the crane driver (and
maintenance personnel) shall be provided.

A driver cab shall,

22
  Provide adequate protection from the weather,
 Be ventilated and/or cooled,
 Allow clear and unrestricted view for the safety of the lifting operations.
 Every lifting appliance should be properly maintained.
 The inspection & maintenance operations shall be documented & logged.

5.2.4 Load indicator

All cranes shall be fitted with an appropriate load indicator and a load chart. The load indicator shall
be serviceable. The load chart shall allow the crane driver to readily ascertain the safe working load
(SWL) of the crane at the particular boom length and radius at which it is working.
It is the responsibility of the supervisor in charge of the lifting operation to inform the crane
driver of the weight of the load about to be lifted.

5.2.5 Access to cranes

Only the normal means of access between the ground/deck and the crane structure shall be used to
access or leave the crane or the crane cab. It is not permitted to get on or off a crane in motion.
Emergency escape route or equipment shall be used in emergency only (tower cranes).

5.2.6 Daily &pre-operational check

It is the duty of the crane driver to inspect his crane daily when lifting operations are to take place.
The daily checks should be documented and logged. The inspection includes but is not limited
to,
 Obstruction on tracks (if applicable),
 Signal lights & horns,
 Limit & overload switches & alarms,
 Radio & hard wire communication means (if any),
 Crane motion controls,
 Emergency devices control.

Before leaving the crane, the crane driver shall ensure that,

 The load is removed and the hook(s) is (are) raised to the highest position,
 There is no risk of spurious move of the crane,
 The power supply is shut off,
 The windows and door of the cab are closed and locked.
 The engineering/maintenance department shall check each crane, regularly and at the
beginning of a contract. Reference should be made to the inspection & maintenance
procedures.

5.3 CRITICAL LIFT PERMIT

23
PLANNED CRITICAL LIFT PERMIT – means this permit, including the terms and conditions
contained in this permit and includes supporting

Documents which must be completed prior to a Planned Critical Lift.

CRITICAL LIFT DEFINITION – A lift which involves multiple crane lifts, lifts over operating
facilities where they may endanger personnel, lifts over or close to power lines, lifts involving
personnel cages, lifts exceeding 20 tones, lifts which meet or exceed 85% of the maximum rated
loads, a lift over an occupied building, a lift from a berth deck, or a lift adjacent to sheet pile edge.

CRITICAL LIFT CHECK LIST

CRITICAL LIFT CHECK LIST
CRITERIA

LOAD EXCEEDS 75% OF LOAD CHART FOR CRANE OR DERRICK

TWO OR MORE CRANES / BOOMS REQUIRED

SPECIAL HOISTING / RIGGING EQUIPMENT WILL BE UTILIZED

OTHER – SPECIFY:

DESCRIPTION OF OBJECT TO BE RAISED

DATE OF LIFT:

HOW THE WEIGHT OF THE OBJECT WAS OBTAINED

CERTIFIED SCALE WEIGHT: TICKET #

CALCULATED BY MORE THAN ONE SOURCE

SOURCE: WEIGHT:
SOURCE: WEIGHT:
IF THE LIFT IS AN EXISTING ITEM BEING REMOVED OR DEMOLISHED , THE WEIGHT IS TO BE
RECALCULATED , TAKING INTO ACCOUNT ALL MODIFICATIONS INCLUDING INTERNAL, AS WELL AS AN
ALLOWANCE FOR SCALE, SEDIMENT, SLUDGE, INSULATION, LIQUID, ETC.
SOURCE: WEIGHT:
SOURCE: WEIGHT:

DESCRIPTION AND WEIGHT OF ALL RIGGING EQUIPMENT AND CRANE ATTACHMENTS FROM LOAD
CHARTS

ITEM: WEIGHT:
ITEM: WEIGHT:
ITEM: WEIGHT:
ITEM: WEIGHT:
ITEM: WEIGHT:
ITEM: WEIGHT:

24
 TOTAL WEIGHT OF OBJECT, RIGGING, AND LOAD CHART DEDUCTIONS

SOURCE: WEIGHT:

EQUIPMENT AND LIFT RELATIONSHIP

CRANE # 1 MAKE

MODEL

MAXIMUM OPERATING RADIUS

PLANNED OPERATING RADIUS

ALLOWABLE LOAD (FROM LOAD CHART)

RATIO OF LIFT TO ALLOWABLE LOAD

CLEARANCE BETWEEN BOOM AND LIFT

CLEARANCE TO SURROUNDING FACILITIES

CLEAR PATH FOR LOAD MOVEMENT CHECKED

CRANE # 2 MAKE

MODEL

MAXIMUM OPERATING RADIUS

PLANNED OPERATING RADIUS

ALLOWABLE LOAD (FROM LOAD CHART)

RATIO OF LIFT TO ALLOWABLE LOAD

CLEARANCE BETWEEN BOOM AND LIFT

CLEARANCE TO SURROUNDING FACILITIES

CLEAR PATH FOR LOAD MOVEMENT CHECKED

5.4 Personnel

5.4.1 Discipline Engineers/Technicians

All Discipline Engineers/Technicians are responsible for:

Those personnel who directly supervise any lifting operation are responsible for ensuring that all
materials are handled in a safe and correct manner and in accordance with this Procedure.

5.4.2 Safety Officer and Safety/Environment Engineer

The HSE Officer /Supervisor are responsible for monitoring safe working practices on site

5.4.3 Operator

The crane operator must be in possession of a current Government Crane Operator’s License. In
addition, he must be fully familiar with and competent to operate the particular type of crane to

25
which he is assigned. The HSE department shall test the operator prior to commencement of his first
lifting operation and issue a certificate.
 An operator may be certified to operate more than one type of crane, but under no
circumstances is an operator permitted to operate a crane for which he has not been
certified.
 The contractors supervisor must ensure that his operator is physically fit and mentally
alert. If the operator demonstrates any signs of illness, he must be immediately
removed from the crane.
 The crane operator should attend in HSE lifting and rigging courses. After passing the
courses, he should pass the theory exams and after this , he has to pass the practical
exams. The certificate will be issued after these exams according to his license and exams
results.
 A crane shall not be driven except by a person specially appointed.
The crane drivers shall be,
 Able to show a certificate of medical fitness, with particular regard to stature,
eyesight, hearing and reflexes,
 Able to show evidence of crane driving competence & experience (crane driving
license or any equivalent documentation),
 Adequately trained in the operation of the type of crane they will have to drive,
 Able to carry out the daily checks,
 Able to understand the signals & the language of the signal man,
 Able to make the decision whether or not a lifting operation is safe.

5.4.4 Signalman
The signalman,
 Supervises the lifting operations,
 Is responsible for the safety of the whole lifting operation,
 Shall have been trained in the job or shall be able to demonstrate his ability &
experience,
 Shall ensure the riggers operate safely and follow the basic rules for safe lifting (use
of tag lines, means of escape, safe location, etc.),
 Shall ensure that personnel not involved with the lifting operation is kept well
away,
 Shall keep visual or radio communication with the crane driver,
 Shall ensure that he is identified & fully understood by the crane driver and by the
riggers.

If, at anytime, the signalman must leave, the lifting operation shall be interrupted.
The signal man should stand in a safe position, preferably facing the crane driver, where,

 He can escape from,

 He can be seen by the crane driver,
 He can see the load, the loading area and his riggers.

26
5.4.5 Riggers

 The rigger shall be responsible for properly attaching the load to the crane and for
giving the correct hand signals to the crane operator.
 The rigger must be adequately trained in all techniques of rigging, be conversant with
the standard lifting hand signals and with the general capabilities of the crane with which
he is working.
 The HSEdepartment shall certify the riggers capabilities by performing a test prior to
his first day of work at site.

The riggers,
 Attach & remove the lifting gears (slings, shackles, tag lines, etc.),
 Attend the tag lines of loads being lifted,
 Shall be medically fit, with particular regard to strength, agility, eyesight, hearing &
reflexes,
 Shall have received minimum training or shall have experience of lifting,
 Shall be able to select lifting gears suitable for the loads to be lifted,
 Shall be able to understand the language of the signalman.
5.5 Crane Operations

5.5.1 Crane operation precautions

The signalman is responsible for the safety of the lifting operation.

The crane driver is responsible for the safe operation of the crane. He is fully entitled to refuse to
commence a lift, which from his judgment, is not safe.

The crane driver shall,

 Ensure that the SWL of the crane and lifting gears is not exceeded at any time,
 Ensure that the weight of the load is taken smoothly to prevent boom or rope
failure,
 Ensure that the loads are not dragged or pulled sideways,
 Ensure that slewing is done slowly and that there is sufficient clearance between the
crane moving parts and fixed objects nearby,
 Not lower or raise the crane hook when it is out of sight, unless directed by the
signal man,
 Not allow anyone to travel on the load or on the crane hook,
 Ensure that the riggers stay well clear of the load.

In case of sudden illness, the crane driver shall stop the operation, call for help and wait until
help arrives. In case of special lifting operation, a skilled mechanic attends in the crane cabin.

27
5.5.2 Crane Operators

Crane operators must:

 Be over 18 years of age and be trained and certified in crane operations and
slinging.
 Be adequately trained in the operation of cranes, both the general principles and the
specific type of machine he is required to operate.
 Be familiar with safe working practices applicable to crane operation.
 Be medically fit with normal muscular reflexes.
 Be able to read and understand Operating Instructions and Procedures.
 Have a working knowledge of safe slinging practices.
 Be familiar with and act upon the signals used for the control of crane operations
 (refer to attachment # 1, figure # 8).

Have sufficient working knowledge of the crane to enable him to carry out the routine
maintenance checks for which the operator is responsible.
Before any new crane operator is allowed to work on Worksite he should be given a
competence check by the Contractor’s HSE.

5.5.3 Pre Operating Checks

1. Before a crane is allowed to operate on Worksite, its certificate must be reviewed by
the HSE Department. Records of tests and inspections must be available on the site.
2. At the beginning of each shift or prior to a lift, the crane operator must carry out the
following safety checks. (which could be called a checklist).
 Check that all lifting tackle is correctly color coded.
 Check hydraulic and coolant levels.
 Check that the audible alarms are working for overload conditions.
 Check that the load/radius indicator is operating correctly. (No crane with a
capacity of over 1 ton should be allowed to operate without an operational load indicator)
 Check hydraulic actions, operating motions and braking system.
 Check the crane cabin to ensure that no materials that constitute a fire hazard are
present. Ensure a fire extinguisher is present.
 Check radio communications (if the operator and banksman are not in visual
contact throughout the complete lifting operation.)
3. Before a lift is undertaken the crane operator must know the Safe Working Load
(SWL).

5.5.4 Operations

During crane operations check the following:

 Unusual noises, loss of power or slow response to controls.

 All gauges for proper readings.
 The hoist drum; to ensure that the wire rope is spooling properly.

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5.5.4.1 Wind Speed and Visibility

1. When wind speeds exceed 35 knots extreme caution must be taken.

2. When wind speed exceed 40 knots (refer to Below Table for wind speed conversions),
operations may only proceed with the permission of Site Manager or a responsible person
delegated by him.
WIND SPEED CONVERSIONS
Meters per Second Miles per Hour Knots

5 11 9

10 22 19

15 34 28

20 45 37

25 56 47

30 67 56

35 78 65

40 89 75

45 101 84

50 112 93

3. Prior to permission being given consideration must be given to, but not limited by,
the following:
 Weather forecast.
 Sea State
 Wind Direction
 Type of lifting operation
 Visibility (especially during weathers of darkness)

4. The manufactures instructions must always be followed. In weather which causes

inadequate visibility, crane operations must be suspended.

5.5.4.2 Emergencies

Crane activities must cease in the event of any emergency or potentially dangerous
situation. The crane operator must obey the emergency stop signal whoever gives it.
5.5.4.3 Lifting Tackle

Latches or safety bolts on hooks must be always used. All loads must be checked for
correct slinging prior to lifting and all pipe work should be pre-slung.
Only certified lifting tackle should be used.
The crane’s hook must not be used to lower, raise or carry people; the correct

29
 equipment for carrying out such an operation is the man basket.

5.5.4.4 Suspended Loads

Loads must never be left suspended for longer than is absolutely necessary. When loads
are left suspended, the crane controls must never be left unattended.

PERSONNEL MUST NEVER BE ALLOWED TO BE UNDERNEATH A SUSPENDED

LOAD

5.5.4.5 Crane and Load Movements

Loads must be lifted gently and the crane motions operated smoothly to avoid loads
swinging.
In general lifting across "live" process plant is forbidden. Permission should be sought
from the site manager. Special precautions may be necessary and procedures
produced.
If the rope becomes slack on the drum, cross coiled, or trapped, lifting operations must
be suspended until the rope is paid out, examined for possible damage and re- spooled
correctly.
For all jib cranes with a capacity over 1 ton, a safe load indicator should be fitted with
audible & visual alarm. The alarm starts when the actual load being lifted is between 90
% & 98 % of the safe working load. In addition there should be an audible alarm outside
the cabin when the actual load is between 100 % & 110 % of the permitted safe working
load.
Operating instruction/manuals & special procedures must be available in the crane cabin
& supervisors office.
rior to slewing if personnel are at risk. Where practicably possible, tag lines must be
attached to heavy, long or awkward loads.

5.5.4.6 Communications

The normal method of communication between the banksman and the crane
operator should either be by hand signals or two-way VHF radio.
All hand signals given to control crane operations, must comply with the Standard Code
of Hand Signals (attachment # 1, figure # 8). These must be clear, distinct, easily seen
by the crane operator.
Only the person in charge of the lift may give signals to the crane operator (except in
an emergency).

Blind lifting

It would be wanted to draw the attention of owners of mobile and fixed facilities so as to
facilitate prudent material handling when using cranes and other lifting appliances.

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 Material handling using cranes and other lifting appliances should be organized such that
blind lifts do not occur. This means that the companies must handle the problem in a
systematic manner.

Results and conclusions from thorough material handling analyses must be applied when
designing facilities and in the practical organization of storage and lifting areas.

The operators of cranes or other lifting appliances should have free visibility to the
load in every working/crane position, so that no areas where routine lifts are planned will
have blind zones.

5.5.4.7 Safe Working Load and Maximum Working Radius

The Safe Working Loads (SWL) of the crane must not be exceeded except for the
purpose of a test, and then only by a qualified test engineer, conforming to the crane
manufacturer's specifications and recommendations.
The maximum working radius of a crane boom must never be exceeded with a load on
the crane hook.
When a load is equal, or nearly equal to the Safe Working Load, the load should be
temporarily halted when just clear of the area to check the balance and security of the
load and the effectiveness of the brake.
5.5.4.8 Restrictions on Crane Operations

Normal crane operations will be restricted during the following:

When lifting over live process plant. Permission must be obtained from the Site
Manager. Extra safety precautions may be necessary.

5.5.4.9 Shutdown

On completion of the work, the crane boom and hook must be properly secured on the
boom rest and the motors stopped, before the operator leaves the crane.

Furthermore:
Before leaving his crane unattended, the operator shall:

a. Land any attached load, bucket, or other device

b. Disengage clutch
c. Set travel, swing, boom brakes, and other locking devices
d. Put controls in the OFF position
e. Stop the engine
f. Secure crane against accidental travel
g. When wind alarm is given or on leaving crane overnight, set ground chocks on
truck and crawler cranes
h. Lower crane booms to ground level or otherwise fasten securely against
i. displacement by wind loads or other outside forces

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 j. If there is a lockout/tagout sign on the switch or engine starting controls, the
operator shall not close the switch or start the engine until the warning or lock has
been removed by the person placing it there
k. Before closing the switch or starting the engine, the operator shall see that all
controls are in the OFF position and all personnel are in the clear
If power fails during operation, the operator shall:

l. Set all brakes and locking devices

m. Move all clutch or other power controls to the OFF position
n. If practical, the suspended load should be landed under brake control

5.6 Inspection and Certification Guidelines

All cranes and associated lifting gears must be thoroughly examined and tested in accordance
with this document; all tests and examinations must be properly documented.

The controls are implemented by various methods, including routine periodic inspections
of equipment in service, periodic inspection audit of conditions and usage of equipment;
verification of serviceability of new and in-service equipment by testing, where
appropriate; and maintenance of certification records and inspection histories for various
categories of equipment.

Contractor is responsible for ensuring that all its equipment is properly tested and certified,
is fit for its intend purpose, and is maintained and inspected at appropriate intervals.
Nevertheless, should immediately bring to the attention of any item of equipment
which is in need of maintenance, or which is found to be overdue for test or inspection.
Contractor is responsible for ensuring that all its equipment is properly tested and
certified, is fit for its intend purpose, and is maintained and inspected at appropriate intervals.

Inadequately certified equipment shall be refused for entry and service. Also, while
equipment is in service, POGC may undertake inspections or certification audits of
contractor’s equipment, and shall have the right to quarantine, or to place operational
limitations on, any such equipment which is inadequately certified or is considered unfit
for service.

5.6.1 General

This includes all manner of lifting equipment including, such as cranes and lifting appliances;
wire or fiber ropes; loose gear such as slings (wire or fiber) and shackles; transportation
containers and associated rigging; transportable tanks; winches; hoists and pulling devices;
hydraulic jacks; runway beams and spreader beams; tool lifting clamps; pad eyes and
eyebolts; and skid frames which are used for transportation.

The term “test certificate” normally means a certificate of proof load test, witnessed and
signed by a competent lifting equipment certified supervisor. Certain types of equipment
require periodic re-test and re-certification (e.g. cranes, containers – see below), while other

32
 equipment has no requirement for periodic re-test but may require re-testing after significant
repair or modification.

Proof-load testing will be performed in accordance with relevant industry standards for the
specific type of equipment – typically these include British Standards.
The term “inspection report” normally means a record of examination (visual / functional)
by a competent lifting equipment engineer. Inspection reports have a maximum validity
of six months, unless the inspecting engineer specifies any further limitation of validity.
As proof-load testing will also involve” examination after test, a test certificate is
effectively also considered valid as an inspection report, for a period of six months from
the date of test.
Permissible load capacity and date of next inspection should be writing on both side of
crane.
For equipment tested or inspected by an engineer, the lifting equipment engineer should
be suitably approved by the local authorities.
For equipment tested or inspected in Iran, the lifting equipment engineer shall be formally
authorized by Company Inspection department.

Signed originals of all test certificates and inspection reports should be provided. If for
whatever reason it is not possible or practical to supply the original, any photocopies
supplied should be endorsed / signed by a party who has seen and verified the original
document, or by the party issuing the original document.
The terms “certificate of conformity” or “type approval certificate” refer to different forms
of statement by a manufacturer that equipment is in accordance with specified standards.
With very few exceptions, as noted below, such certificates are not acceptable for
materials for offshore and onshore sites use.

5.6.2 Basic Requirements for Inspection Documents

1. For general equipment (e.g. wire rope slings, shackles, chain blocks, winches,
etc…):
a. A test certificate when equipment is new, and after any significant maintenance,
repair or modification (test load ranges from 1.1 to 2 x SWL).
b. An inspection report, inspection to be undertaken every six months. See note above
concerning six-month validity of a test certificate in lieu of an inspection report.

2. For transportation equipment (e.g. containers, boxes, tanks, baskets, skid units,
etc…):
a. A test certificate when equipment is new, and after any significant maintenance,
repair or modification (test load ranges from 1.1 to 2 x SWL).
b. An inspection report, as for (1.b) above.

3. For fiber slings (inc. fiber ropes, cargo nets, jumbo bags, etc…):

33
 a. Type approval certificate with measured breaking load for similar item. Physical
proof-load testing is usually not practical as damage to fibers cannot be accurately
assessed.
b. An inspection report, as for (1.b) above.
4. For cranes and fixed lifting appliances:
a. A test certificate when equipment is new, at 1-year intervals, and after any
significant maintenance, repair or modification (test factor dependent on SWL,
typically 1.25 x SWL up to 20T, reducing progressively above 20T).
b. An inspection report, inspection and functional test to be undertaken every
six months.

5. For wire ropes (including crane ropes, winch ropes, etc…):

a. Test certificates when equipment is new, comprising a breaking test certificate for
the rope (equivalent to Form 87 under UK Statutory Instrument 1019). Proof test
on terminations to be repeated in the event of significant maintenance, repair or
modification (2 x SWL proof load for terminations).

Breaking test
a break test can be performed on the wire rope. This is accomplished by cutting off
sections of the wire rope and placing each section of the rope on a wire rope break test
machine. The machine pulls the wire rope apart and computes the breaking
strength. By testing several sections of the wire rope, you can determine the average
breaking strength for that type of wire rope.

Proof test
A nondestructive tension test performed by the sling manufacturer or an equivalent
entity to verify construction and workmanship of a sling.

b. An inspection report, as for (1.b) above.

Note : A third party inspection agency shall review inspection documents .

5.6.3 Basic Requirement for Equipment Marking

All equipment must be marked with an identification number(as mentioned in wire rope
section) , which can be unambiguously correlated to the appropriate certification or
reports. In most cases, this will mean a unique reference number per item. All
equipment must also be marked with the relevant Safe Working Load (SWL), or for
transportation equipment, the Maximum Gross Weight (MGW).

All equipment must be color coded. Logistics department, before authorizing any lifting
equipment entry, shall check the above required documents and shall visually inspect
all items.

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 Upon satisfactory checks, a color code label (colored strap/paints…) will be put on all
inspected lifting equipment by logistics representatives.

A common color code should be used on all premises. Validity periods and color
identification shall be given by HSE department.

Any lifting equipment found on or delivered to the Worksite without the above
required certification documents and without valid color code label in place will be
immediately removed from service and placed in quarantine until such times as the
relevant documentation is supplied.
5.7 Man Basket Safety Rules
Where scaffolds cannot be used for specific elevated works, cranes shall be used to raise
or lower personnel in specially fabricated cages (man baskets), approved by HSE
Department, which are:
 Properly designed by a qualified engineer and well constructed and maintained.
 Have means to stop personnel from falling out.
 Prevented from spinning or tipping.
 Be operated from one position only.
 All personnel within such cages (man baskets) shall wear a full safety harness which
shall be attached separately to the crane hook ball by an approved lanyard.
 A work permit, together with a detailed method statement approved by HSE
Department, shall be required.

5.7.1 Basket Loading

 The personnel man-basket shall not be loaded in excess of its rated load capacity.
 The number of employees occupying the personnel man-basket shall not exceed
the number required for the work being performed.
 Personnel man-basket’s shall be used only for employees, their tools, and the
 materials necessary to do their work, and shall not be used to hoist any materials or
tools when not hoisting personnel.
 Materials and tools for use during a personnel lift shall be evenly distributed within
the confines of the man-basket while it is suspended.
 Traveling the crane while personnel are in a hoisted man-basket is prohibited.

5.7.2 Rigging for Man Baskets

 When a wire rope bridle is used to connect the man basket to the load line, each bridle
leg shall be connected to a master link or shackle in such a manner to ensure that the
load is evenly divided among the bridle legs.
 Hooks on overhaul ball assemblies, lower load blocks, or other attachment assemblies
shall be of the type that can be dosed and locked, eliminating the hook throat opening.
Alternatively, an alloy anchor type shackle with a bolt, nut and retaining pin may be
used.

35
  Wire rope, shackles, rings, master links and .other rigging hardware must be capable
of supporting, without failure, at least .five times the maximum intended load applied
or transmitted to the component.
 Where rotation resistant rope is used, the slings shall be capable for supporting
without failure at least ten times the maximum intended load.
 All eyes in wire rope slings shall be fabricated with
thimbles.
 Bridles and associated rigging for attaching the man basket to the hoist line shall be
used only for the man basket and the necessary employee, their tools and the materials
necessary to do their work, and shall not be used for any other purpose when not
hoisting personnel.

5.7.3 Inspection of Man Baskets

Prior to the man basket being used the 'Man Basket Check list must be completed by the
respective contractor in the presence of HSE Department personnel.
The requirements of the 'Man Basket Checklist' (Attachment # 2) shall be adhered to .

5.7.4 Trial Lift and Inspection

 A trial lift shall be performed immediately prior to placing personnel on platforms.

 The operator shall determine and confirm that all systems, controls and safety devices
are activated and functioning properly, that no interference exist, and configuration
necessary to reach the work locations will allow the operator to remain under 50%
limit of the hoist rated capacity.
 A single trial lift may be performed at one time for all locations that are to be reached
from a single set up position for the same radius.
 The trial lift shall be repeated prior to hoisting employees whenever the crane is
moved and set up in a new location.
 The trial lift shall be repeated when the lift route is changed unless the operator
determines that the route change is not significant, that is the route change would not
affect the safety of the hoisted personnel.
 The operator shall, prior to hoisting personnel, first hoist the platform a minimum of one
meter (1m) to ensure that it is secure and properly balanced.

The following must be confirmed:

 Hoist wires shall not be kinked

 Multiple hoist wires shall not be twisted around each other.
 The primary attachment shall be centered over the platform.
 The hoisting system confirmed that the load wire is not slack, and ensure all wires are
properly secured on the drums and sheaves.
 A visual inspection of the crane, rigging, personnel platform and the crane base
support or ground shall be conducted by a Competent Person immediately after the

36
 trial lift to determine whether the testing has exposed any defect or produced any adverse
effect upon any component or structure.
 Any defects found during inspection which create a safety hazard shall be corrected
before hoisting personnel basket:

5.7.5 Safety Rules for Men in the Basket

The following rules must be explained to the personnel being lifted within the man-basket:
 Employees shall keep all parts of the body inside the man-basket during raising,
lowering, and positioning. (NOTE) This provision does not apply to an occupant of
the man-basket performing the duties of a signal person.
 Before employees exit or enter a hoisted personnel man-basket that is not landed, the
man-basket shall be
 secured to the structure where the work is to be performed, unless securing to the
structure creates an unsafe
 situation.
 Tag lines shall be used unless their use creates an unsafe condition.
 Employees being hoisted shall remain in continuous sight of and in direct
communication with the operator or signal person. In those situations where direct visual
contact with the operator is not possible, and the use of a signal person would create
a greater hazard for that person, direct communication by radio must be used.
 Employees occupying the personnel man-basket shall use a full body harness
system with double lanyard appropriately attached to the Hook or overhaul ball of the
crane or to a structure member within the personnel platform capable of supporting a fall
impact for employees using the anchorage.
 No lifts shall be made on another of the crane's or derrick's load lines while
personnel are suspended on a man basket.

5.7.6 Safety Rules for the Crane Operator

 Hoisting of the personnel man-basket shall be performed in a slow, controlled,

cautious manner with no sudden movements of the crane or the platform.
 Load lines shall be capable of supporting, without failure, at least seven times the
maximum intended load, except that where rotation resistant rope is used, the lines shall
be capable of supporting without failure, at least ten times the maximum intended load.
The required design factor is achieved by taking the current safety factor of 3.5 and
applying the 50 per cent de-rating of the crane capacity.
 Load and boom hoist drum brakes, swing brakes, and locking devices such as pawls
or dogs shall be engaged when the occupied personnel man-basket is in a stationary
working position.
 The crane shall be uniformly level within one percent of level grade and located on firm
footing. Cranes equipped with outriggers shall have them all fully deployed following
manufacture’s specifications, insofar as applicable, when hoisting employees.
 The total weight of the loaded personnel man-basket and related rigging shall not
exceed 50 percent of the rated capacity for the radius and configuration of the crane.

37
  The crane operator shall remain at the controls at all times when the crane engine is
running and the man-basket is occupied.
 Hoisting of employees shall be promptly discontinued upon indication of any
dangerous weather conditions or other impending danger.
 No lift shall be made on another of the crane or derrick’s load lines while
personnel are suspended in a man-basket.

5.8 Mobile Working Platforms

5.8.1 Definitions

Mobile Elevating Work Platforms (MEWPs).

a) Mobile elevating work platforms are often used as an alternative to ladders, scaffolds
and cradles. They are particularly suitable for short duration tasks requiring a work platform
as they are easily moved from place to place. A variety of types are available and guidance
on specific applications should be sought from the manufacturers.

b) Work platforms may be towable units, lorry or trailer-mounted or self- propelled.

Self-Propelled.

This type of platforms is available in three main types-scissors, teleboom and articulated
boom. They are normally used on construction sites or for maintenance on existing buildings.
Some of these platforms have been specially developed so that they can fit through a
standard doorway to allow access to the most restricted areas.
They can normally be obtained in diesel or electric powered models with some having
the option of running on petrol or propane.

Vehicle-Mounted.

c) This type of platform can be obtained in various sizes from small trailer- mounted
platforms to large truck-mounted ones. The two most common types are the van-mounted
and truck-mounted platforms. Van-mounted platforms are normally used for access on or
from highways, a common use being the servicing of street lighting. Truck-mounted
platforms are normally used where access by other methods is too expensive or time
consuming.

d) There are other vehicle-mounted platforms that have been developed for specialized
applications including all-terrain and under bridge work platforms.

e) All-terrain platforms are often dumper-mounted to allow the vehicle access to

positions where only off-road vehicles can reach. Under bridge units were specially
developed for inspection of bridges which cannot be accessed easily by other means.

Mast Climbing Work Platforms (MCWPs)

38
 Mast climbing work platforms (MCWPs) allow access to a localized area of a construction
project. The rack and pinion drive gives an adjustable working platform, which can be
positioned exactly to suit the task in hand. Tools and materials can be carried up to the work
site, together with the operatives. MCWPs must not be used for transferring men and
materials between levels. An appropriate hoist should be used for this.

MCWPs consist of three main components:

f) Mast(s) or tower(s) which support(s) a

platform or cage. The mast or tower may be in
one piece or constructed from separate sections.
g) A platform capable of supporting persons and equipment.
h) A chassis supporting the tower/mast structure. The chassis may provide stability
for the machine with or without outriggers, up to a specified free-standing height, above
which the mast must be tied to a building or other structure.
i)
j) MCWPs are available in various configurations with:
k) Single or twin masts.
l) Mobile or static chassis.
m) Freestanding or tied-in mast.
n) Variable length working platforms.
o) Single or twin storey working platforms.
Man-riding Skips and Cradles

Man riding skips or cradles can be used to gain access to structures or as working
platforms. The skip/cradle must be suitable for the intended purpose, e.g. if the skip is
used for access into a shaft or cofferdam it should have a roof to protect the occupants
from falling objects.

The crane used must have a dead-man’s handle; this means that the brake is applied
automatically when the control lever or switch is not held in the operating position.
The crane must not be capable of lowering by free-fall.

This means that the conventional crawler crane with separate clutch control and footbrake
is not suitable for use with man-riding skips.
5.8.2 Instructions
Operation of MEWPs. (Mobile Elevating Work Platforms)

a) Operatives must be specifically trained and authorized to operate a particular class

of mobile work platform and a record should be kept of authorized persons and
the training they have received. The mobile work platform must be used strictly
in accordance with the manufacturer’s instructions and company operating
procedures. Safe working loads, the permitted number of persons on the platform and
maximum wind speeds must not be exceeded.

39
 b) Consideration should also be given to the sitting and stability of the platforms,
especially on uneven ground of soft ground and on slopes where the danger of
overturning exists. When outriggers are to be used, the load bearing capacity of the
ground should be ascertained and a check made for drains, cellars and other
hazards which may affect the safety of the work platforms.

c) Use of mobile work platforms.

1) Do
 Take care not to come into contact with overhead obstructions when elevating the
platform.
 Wear a suitable safety harness in boom type machines.
 Use outriggers where fitted.
 Make sure that MEWPs are regularly inspected by a competent person and that records
are kept.

2) Do not
 Leave a platform or cage except at the proper disembarkation point.
 Use MEWPs to transfer materials from one level to another. If they are used for this
purpose, they are classified as hoists and require significant modifications.

Use of MCWPs.

a) MCWPs should only be erected by skilled and competent persons and should only
be used by trained operatives.

b) MCWPs should be inspected daily before use by the user.

c) MCWPs should be regularly inspected by a competent person and records of
inspection should be kept.

d) MCWPs should be clearly marked with the safe working load and permitted
number of persons allowed on the platforms at each configuration.

e) The manufacturer’s instructions on inspection, maintenance and servicing must be

followed at all times.

f) The operator should not carry out repairs and adjustments unless qualified and
authorized to do so.

g) Safe means of access to the platforms should be provided at its lowest level. This
may be by a short fixed ladder, raised platforms or by control arrangements which
allow the platforms to be brought down to ground level.

h) Ground conditions must be checked for adequate bearing.

40
 i) A safety barrier must be erected to exclude personnel from the area below the
platform

Use of Man-Riding Skips

b) Personnel must remain wholly within the skip or cradle when it is being lifted or
lowered-do not climb or ride outside.
c) Safe working load should be displayed inside and outside the skip or cradle.
d) Make sure there is good communication between the passengers and the crane
driver. 2-way radios may be required.
e) When used for access:
Provide a firm level surface where the skip or cradle is to be landed. The surface must
be wide enough to fully support it.
Enter or leave the skip or cradle one person at a time.
The alighting area should be big enough to allow people to climb in and out of the skip or
cradle easily and safely. Provide guardrails where appropriate.
Provide a safe means of access from the landing place to the place of work.

f) Do not leave the skip or cradle at height unless you are wearing a safety harness or
belt.
g) The safety harness should be clipped to the crane hook block when traveling or
working in the man-rider and to the structure when leaving the man-rider.
h)
Notice: All required principles for safe use of fixed lifting equipment has been
mentioned in this procedure and they could be applied to Mobile lifting
equipment too, so it has been avoided to repeat them.
5.9 General Safety in Rigging and Lifting:

5.9.1 Safe Work Systems

 Contractor shall ensure that a safe system of work shall be laid down and effectively
communicated to all personnel involved in a lifting operation. It shall include but not
limited to:
 Thorough planning of the operation, along with the selection, provision and use of
 suitable cranes and equipment.
 The maintenance, testing and examination of all equipment.
 Supervision by trained and competent personnel, together with all necessary
 authority to progress or stop a job as necessary.
 The provision of all test certificates and other documentation relevant to the
equipment being used.
 The prevention of unauthorized use or movement of equipment, by unauthorized
workers.
 The safety of all personnel, those involved in the lift as well as those not involved in
the lift, but who may be affected by the lifting operation.

41
 5.9.2 Signals

 Every crane operation shall be accompanied with a trained signaler to provide

clear and distinct signals to the crane operator. The signaler shall be clearly identified
by wearing a green colored vest.
 Signaling communications may be by standard hand signals (attachment # 1, figure
#8), whistles and radio communications and shall be discernable at all times.
Radios shall be licensed by the relevant authorities and the requirements of the
license be strictly complied with.
 Radio communications shall be such that clear and precise words of command shall
be given, so that there can be no misunderstandings between the signaler and the
crane operator.
 The use of hand signals, as guide-lined in Attachment, shall be equally clear
and distinct.

5.9.3 Rigging a Load with Rigging Equipment

 The Contractor's rigging personnel (Appointed Person) shall ensure, that when
rigging a load with rigging equipment, the following is observed;
 The weight of the load is determined and not guessed.
 Sling capacities and equipment are checked and confirmed as suitable for the load
to be lifted.
 Shackle pins and shouldered eyebolts are installed in accordance with the
manufacturer's instructions.
 Sharp edges are padded to prevent damage and/or cutting of the sling.
 Slings, eyebolts, shackles, hooks etc. have not been modified, cut, welded or
brazed.
 The center of gravity and balance of the load has been determined, prior to moving
the load, and the attachment. Points of the rigging accessories are as far as practical
from the center of gravity.
 Initially the load is trial lifted, approximately 150mm from ground, to test the
rigging and balance of the lift.

5.9.4 Safety during Crane Operations

 The Subcontractor's rigging personnel shall ensure, that when preparing a load for
lifting, the following is observed;
 A preoperational check has been made to the crane and rigging equipment.
 That any practice which may interfere or divert the attention of the crane operator
or rigging personnel is ceased.
 Method of communication using hand signals and/ or radio contact has been
agreed between the crane operator and the signalman.
 The crane operator shall only respond to signals from the appointed signal man.
 The load shall not be suspended over any person and the area over which the load
is suspended shall be checked and evacuated of all personnel.

42
  Watch for obstructions and overhead facilities such as pipe-racks and/or power
lines.
 Ensure that a Preliminary Hazard Analysis is completed for all lifts over 20 tons
and/ or over live equipment.

Crane Pitch Points

Grooves should be smooth and slightly larger than the rope to prevent it from being pinched
or jammed in the groove.

Jib/boom hoisting sheaves should have pitch diameter of not less than 15 times the nominal
diameter of the rope used.

Load hoisting sheaves should have pitch diameters not less than 18 times the nominal
diameter of the rope used, and the load block sheaves should also have pitch diameters not
less than 16 times the nominal diameter of the rope used.
Depth of sheave grooves should be at least 1.5 times the rope diameter, and the tapered side
walls of the grooves should not make an angle of more than 18 degrees with respect to
the centre line.
Bearings should be permanently lubricated or be equipped with means for lubrication.
Sheave should be equipped with cable keepers or close fitting guards to prevent the
rope from leaving the groove .

5.9.5 Preliminary Hazard Analysis

All crane lifts exceeding 20 tons shall be subject to a Preliminary Hazard Analysis. Once
the hazards have been identified, the Subcontractor shall remove or reduce those hazards
as far as reasonably practicable.
All critical lifts exceeding 100 tons, irrespective pf crane lifting capacity or lifting radius,
shall require a detailed rigging study submitted for approval to contractor and reviewed by
Company. Of course, JHAMs would be considered (section 6.6: Lift Plan) and should be
registered .

5.9.6 Drums and Pulleys

The size of the crane's drums or pulleys must. match the size of the wire rope being used.
The wire rope must be anchored to the drum and there shall benever less than two ' dead'
turns on the drum.

5.9.7 Brakes, Controls, Etc.

Crane, winches, etc. must be fitted with brakes capable of holding and controlling the
maximum load. Controls on all lifting devices must be clearly marked so that they cannot be
operated accidentally.

5.9.8 Cranes with Derrick Jibs

43
 If the derrick motion of a crane is driven by the hoist motor through a clutch, and can only
be controlled by the hoist brake, an interlock must be fitted to prevent dual operation.

5.9.9 Location of Cranes and Lifting Appliances

The Construction Manager shall decide on the location of cranes or other lifting appliances
but, in the case of mobile cranes, the operator is responsible for ensuring that the
movement and position of the crane are both safe and suitable.
The crane operator shall be responsible for checking that any ramps, slopes or
overhead lines do not cause an obstacle or danger, and that refueling or other vehicles can
gain access without causing a hazard.
A 600mm wide clearance between traveling or slewing cranes and any fixture (guardrail,
scaffold, walkways, etc.) must be maintained; where this is not practical, any place where
persons can be trapped must be enclosed by barriers.

5.9.10 Overhead Power Cables or Pipe-racks

Particular care shall be taken when locating cranes or lifting appliances near overhead power
cables. The jib or boom must not be raised near to and/or touch a live power
cable or a "flashover" may occur. A "flashover" can occur over considerable distance,
depending on the voltage carried by the overhead cables.
The minimum recommended safe working distance away from overhead cables is the length
of the jib of the crane, plus 6 meters, measured with the jib pointing towards the cable, even
when the crane will be working in the opposite direction.
If the minimum safe working distance cannot be maintained, the electricity supply shall
be switched off or otherwise disconnected by an authorized engineer.
The 'maximum clearance height' fixed at all pipe-racks within the operational plant shall
not be removed without the written approval (Permit to Work, etc.) from the Company.

*Insulated lines

| |
Voltage | Minimum distance | Alternatives
| |
| |
Less than 300 volts| 3 feet (0.9 m) |
300 volts to 50 kv.| 10 feet (3.1 m) |
More than 50 kv....| 10 feet (3.1 m) plus | 2 times the length
| 0.4 inches (1.0 cm) | of the line
| for each 1 kv over | insulator, but never
| 50 kv. | less than 10
| | feet (3.1 m).
| |

*Uninsulated lines

| |
Voltage | Minimum distance | Alternatives
| |
| |

44
Less than 50 kv....| 10 feet (3.1 m). |
More than 50 kv....| 10 feet (3.1 m) plus | 2 times the length of
| 0.4 inches (1.0 cm) | the line insulator,
| for each 1 kv over | but never less than
| 50 kv. | 10 feet (3.1 m).

5.9.11 Stability

Cranes must have stable and level base. The stability and load-bearing capacity of the ground
must be sufficient to carry the most severe static and dynamic loads, taking into account
such factors as the slewing torque, wind stress and shock loading, as well as the weight of
the crane and its load.
Care shall be taken to see that the ground is firm and stable. Excavations which may not
have been correctly filled or ground shafts may reduce the stability of the ground and
constitute a hazard to machinery and heavy loads. The same applies when a crane is sited
on a roadway for the purpose of working into the Work Site.

5.9.12 Outriggers

All crane outriggers must be extended fully and equally on both sides of the crane. Outriggers
are effective only if they are used correctly. The safe rule is to use outriggers for all
lifting duties.
Suitable crane mats must be used under each outrigger in order to spread the load and reduce
the grand area loading.
Particular care shall be taken on ground condition where long jibs are in use as sloping
ground can significantly affect the stability and capacity of crane.

5.9.13 Rigging and De-Rigging of a Crane

No crane or other lifting appliance shall be erected unless under the direct supervision of a
competent person.
The de-rigging of a crane must only be carried out under the supervision of a
Competent Person and as recommended by the crane manufacturer.
Care must be taken to see that nobody stands under any jib section while the
connecting pins are being withdrawn.

5.9.14 Instruments and Components

HSE Department or its nominated representative shall verify that all safety devices installed
by crane and derrick manufactures are still fully operational prior to their use at the work
site.
Cranes and derricks with variable angle booms shall be equipped with a boom angle
indicator, readily visible to the operator.
Cranes with telescopic booms shall be equipped with a device to indicate clearly to the
operator, at all times, the boom extended length, or an accurate determination of the load
radius to be used during the lift shall be made prior to hoisting.

45
 A positive acting device shall be used which prevents contact between the load block or
overhaul ball and the boom tip (anti-two-blocking device), or a system shall be used which
deactivates the hoisting action before damage occurs in the event of a two- blocking situation
(two block damage prevention feature) .
Note : All cranes should be equipped with proper extinguishers .

5.9.15 Crane Markings

All cranes and other lifting appliances must be clearly marked with their Safe Working Loads
(SWL) and date of next inspection . If the lifting radius can be varied, an indicator must be
fitted which shows the safe operating radius of each lift.

5.9.16 Qualification and Competency of Lifting Operators & Involved persons

One person, other than the crane operator, shall be appointed to take responsibility for the
organization and control of any lifting operation. He should have adequate training and
have the necessary experience to be deemed to be competent. .
The appointed person must:
 Assess the proposed lift to provide for planning, selection of equipment, instruction and
supervision to enable the work to be carried out safely.
 Ensure that all tests, inspections, examinations and maintenance have been carried out,
and that there is a procedure for reporting defects and taking whatever corrective action
is necessary.
 Have the authority to carry out his duties to stop the operations if he thinks there is a
danger.
 The appointed person's duties, but not his responsibilities, may be delegated to
another competent person
 Drivers of cranes and other lifting appliances and others involved in lifting
operations, including signalers, must be adequately trained and experienced and aged 18
years and above.
 No one shall be allowed to operate cranes or other lifting appliances within the work
site for the purpose of training, even under the supervision of a competent person.

5.9.17 Restriction on Use

A hoisting mechanism should be used for raising and lowering the loads vertically and for
no other purpose, unless competently supervised and can be done without overstressing the
crane structure and mechanism, or endangering its stability.
Crane jibs shall not be worked at a radius greater than that specified on the test certificate.

5.9.18 Loads

 Loads shall be raised to a height of about 150 mm and held, while the stability of the
crane is assessed, prior to proceeding with the lift.
 Tag-lines shall be mandatory for all lifts.

46
 Loads shall not be pulled in order to free them from their attachments or their
surroundings, as the stress and load exerted to the crane boom cannot be determined
and when a load does break free the sudden shock can result in damage to the boom or
crane machinery, failure of sling or wire, whiplash, and other dangers.
 Jobs that require meticulous planning with precise knowledge of the load, its centre of
gravity and its planned location on the ground, such as the handling of long columns from
the horizontal to the vertical and multiple lift operations shall require written procedures,
setting out the safe system of work to cover such operations. In multiple and tandem
lifting, all loads shall be calculated.
 Loads must be correctly slung and made secure to prevent any part of the load slipping
or falling. Precautions shall be taken to prevent the load striking any obstacle or knocking
anything down.
 Loose materials shall be lifted in a properly constructed box or container.
The operator shall remain at the controls whenever the load is suspended.
 When two cranes or other lifting appliances are used for one load, they must remain
stable throughout the lift. Such multiple lifts shall be supervised by specially appointed
competent personnel and be subject to a detailed rigging study, which has prior approval
from HSE Department.

47
Lifting of hazardous material

Perform security rounds, prevent fires, handle and store hazardous materials, comply with
legislation, operate equipment, wear protective clothing, identify potential safety hazards,
operate emergency equipment, report injuries, advise customers of hazardous materials,
maintain good housekeeping, use hand and power tools, use material handling
equipment, perform store openings and closings, perform recycling duties, use correct
manual lifting techniques and handle and ship air bags.
Perform security rounds and conduct a visual inspection of the equipment prior to use to
insure safe and effective operation, checking component wear or damage, fluid levels
and tire condition in accordance with company policies, manufacturers' recommendations
and government regulations.
Prevent fires by inspecting the work area, removing combustible materials and flammable
products, ensuring that the required fire extinguishers are available and ready for use,
labeling the area with the prescribed warning signs, examining electrical equipment and
cords for signs of wear or overload, in accordance with company policies, manufacturers'
recommendations and government regulations.

Handle, use and store hazardous materials including: paints, solvents, acids,
refrigerants and oils, fuels, propane, acetylene, batteries, cylinders and volatile organic
compounds; securing materials in designated areas, ensuring that waste materials are in
approved containers in preparation for recycling or disposal; to protect self, others, property
and the environment, in accordance with company policies, manufacturers' recommendations
and government regulations.

Comply to the workplace regulations, by interpreting the acts and regulations, and
performing the work in accordance with the requirements of The Occupational Health
& Safety Act (OHSA), Workplace Hazardous Materials Information System
(WHMIS), Workers Compensation Act, the Environmental Protection Act.
Operate equipment safely and effectively to move, load, unload and place stock, including:
forklifts, pump lift carts, dollies and overhead cranes, to protect self, others and property, in
accordance with company policies, manufacturers' recommendations and government
regulations.

Wear protective clothing and equipment ensuring correct fit and application for the
work to be performed, including: kidney belts, safety shoes, skin and eye protection, ear
protection, breathing masks and required ventilation, hard hats and protective suits or
clothing, to achieve optimum protection of self and others, in accordance with
company policies, manufacturers' recommendations and government regulations. Identify
potential health and safety hazards within the workplace by conducting routine
visual inspections to determine fire hazards, obstacles and impediments, spills and leaks
of chemical or liquid products; and, by taking corrective action when

50
required in accordance with company policies, manufacturers' recommendations and
government regulations.

Operate emergency safety equipment correctly including: eye wash stands, fire
extinguishers, hoses, fire alarms and fire doors in order to respond effectively to
emergencies, injuries and accidents by assisting others, activating alarms and signals and by
notifying others in accordance with company policies, manufacturers' recommendations and
government regulations

Report injuries and accidents to immediate supervisor and health and safety Committee,
ensure that all required forms and reports are completed and submitted in accordance with
company policies and government regulations.

Advise customers of hazardous materials by describing their specific uses and explaining the
hazards of misuse of the product involved; and, by providing material safety data sheets for
the specific product to protect others and the environment in accordance with company
policies, manufacturers' recommendations and government regulations.
Practice and maintain good housekeeping by keeping a safe and tidy work area,
clearing away debris, removing obstacles and impediments and storing materials in the
proper location, in accordance with company policies and government regulations.

Use and maintain hand tools safely and effectively, reporting and tagging damaged and
defective tools; and by properly storing tools to protect self and others in accordance with
company policies, manufacturers' recommendations and government regulations.

Use and maintain electric and pneumatic power tools and equipment in a safe and effective
manner, tag and report damaged or defective tools; and store equipment correctly after use
to protect self and others in accordance with company policies, manufacturers'
recommendations and government regulations.

Use and maintain material handling equipment to move and lift stock, including slings,
chains, dollies, pump lift carts and conveyor belts, ensuring that all components are in safe
working order and have the rated capacity for the work being performed, to protect self and
others in accordance with company policies, manufacturers' recommendations and
government regulations.

Perform store/shop opening and closing duties including: operating lighting panels,
checking security systems and fire alarm systems, securing/opening of entrances and exits,
loading docks and truck bay doors, to ensure a safe protected environment for self, others
and property, in accordance with company policies and manufacturers' recommendations.

51
 Perform recycling duties by separating and storing used products until disposal including:
oil, coolant, filters, rags, cardboard, plastics and glass, using the correct bins and containers
and informing others of pick up and disposal to protect self, others and the environment, in
accordance with company policies, manufacturers' recommendations and government
regulations.

Use correct manual lifting techniques when moving stock, wearing a back supporting kidney
belt, keeping the back straight and using leg power when lifting objects from ground level,
to protect self and others, in accordance with company policies, manufacturers'
recommendations and government regulations.

Handle, package and ship air bags and air brake chambers by checking for damage to he
air bag and the carbon dioxide (Co2) canister, ensuring that the specified heavy duty
carton is used, labeling the carton with the significant warning label and completing the
required documentation, to protect self and others, in accordance with company policies,
manufacturers' recommendations and government regulations.

5.9.19 Security When Not In Use

Cranes shall be secured when not in use, to minimize the chance of tampering,
vandalism and damage.
For short periods the operator shall:

 Lower the load to the ground and disconnect it from the lifting gear.
 Raise the jib clear of other operations.
 Chock all the wheels on inclines.
 Apply all brakes and the slewing lock.
 Stop the engine, remove the ignition keys and lock the cabin.
For longer periods, such as end of each working day, at weekends, etc. the operator
shall:
 Lower the load to the ground and disconnect it from the lifting gear.
 Where space permits, swing the jib clear of the load, of other operations and lower
it onto the ground or stable support, taking care not to foul the crane block.
 Where space is limited and the jib can’t be lowered, the hook should be secured to
a suitable or stable anchor (but not to the crane), to prevent slewing in very windy
conditions.
 Apply all brakes.
 Stop the engine, remove the ignition keys and lock the throttle in the closed
position.
 Isolate or lock off all control switches.
 Secure and lock the cabin.

52
5.9.20 Strong Wind and Rainy Conditions

Crane manufactures' operating instructions normally specify a maximum wind speed for
safe operation which may vary depending on the jib length, the radius, the load and other
factors. All proposed lifting operations shall take cognizance of such instructions Crane
operations will cease during rainy conditions.

5.9.21 Chains, Slings and Lifting Gear.

All wire ropes, chains, slings, etc. must be clearly marked, with its Safe Working Load,
color coded as instructed by HSE Department, registered in the wire rope inspection and the
safe working load specified.

All equipments use in lifting operations must be:

 Properly constructed and maintained.
 Free of any defects or damage likely to affect its strength.
 Securely attached to the load to be lifted.
 Inspected by HSE Department or its nominated representative.

5.9.22 Hooks
All crane hooks shall be in good working order and must be:

 Fitted with safety catches.

 Markedwith Safe Working Load.
 Checked for cracks, nicks, bending or excessive wear.
 Free from twisting sideways from the plane of the
unbent hook.
 Free from excessive opening at the throat.
5.9.23 Slings
Slings must be:

 Free from abnormal wear.

 Free from torn stitching
 Free from visible threads from the interior of the sling fabric.
 Free from broken or cut fibers.
 Free from discoloration or deterioration.
 Free from evidence of heat damage.

Slings shall be attached to the lifting appliance correctly by approved methods either by securing
the eye of the sling directly onto the hook if size permits, or by use of a suitable shackle, fitted with
the crown of the shackle on the hook and the pin fully engaged.
The correct method of slinging will vary with the types of loads, the different materials or items
lifted. However, the load must be secured. Care must be taken to see that slings are not damaged
and any suspect or defective slings must be discarded.
53
Multiple sling lifts (two legged, three legged, etc.) must be connected by a ring or shackle
and the load properly distributed so that no leg is overloaded.
The angle between sling legs should be less than 90°. At angles greater than this, the strain on each
leg increases very rapidly to a point where they may break because of overloading.
With a simple two-legged parallel sling lift, the load in each sling leg is half the total load. As the
angle between sling legs increases, the load in each slings increases to approximately double, at an
angle of 1200. With a sling angle of 900, the SWL of the capacity of the sling should be at least 43
% weight of the load.

5.9.24 Tag Lines

Tag lines, securely attached to the end of the load, must be used for all loads to direct the load into
position and prevent it spinning. Tag lines should not be less than 3 meter in length.

5.9.25 Repaired Ropes, Chains, Etc.

Any sling, etc. which has been altered or repaired by welding or other works must be examined and
retested and a new certificate obtained, from a recognized third party inspection agency, before it
can be used.
5.9.26 Knotted Slings and Chains

Knotted chains or slings and those which have been shortened or joined by nuts and bolts through
the links shall not be used.

5.9.27 Unbalanced Load

Particular care should be taken to see that the centre of gravity (point of balance) is in the
approximate centre of the load, with the line of lift passing through it.
An unbalanced load may result in far greater strain on one leg of a sling and cause it to break or the
load to swing out of control.

5.9.28 Shackles

Two types of shackles may be used in lifting operations. They are the Bow type and
Dee type shackles, both of which are available with threaded or plain pins.
Bow shackles should be used when more than. one attachment is to be made, or to allow
movement on the plain of the shackles. Dee shackles are usually joining shackles.
Overloading, eccentric shackle loads, and misuse can distort shackles. They should be checked
regularly for shape and wear.

5.9.29 Eyebolts

Eyebolts, with SWL and specified for lifting purposes, shall be used to screw indoor through a load
and may be plain or have collars. Plain eyebolts shall be used only for vertical loading.

54
Collared eyebolts with links may be used, provided the angle of load to the axis of eyebolt thread
does not exceed 15 degrees.
When installed, the collar must be at right angles to the hole, should be in full contact with the
surface, and be properly tightened. The load should be applied in the plane of
the eye, never in the other direction. If necessary, washers or shims should be inserted below the
collar to ensure that the eye is correctly aligned when tight.
Extreme care must be taken to ensure that metric threaded eyebolts are not inserted in imperial
threaded holes. Although these might appear to match, it is an interference fit only, and the
mechanical strength may be almost nothing.

6. Definitions
A competent person : means a person who, by experience and/or reason of training, is competent
to perform and assume the responsibility to perform a task or function and is designated to perform
such task or function.

Appointed Person (Rigger) means ; An Appointed Person is a person who has adequate training,
authority and experience to take overall responsibility and control of a lifting operation, having been
appointed by the management of the organization requiring the load to be moved. The Appointed
personnel shall be clearly identified by wearing of green colored vests.

Blind Lift : A lift where at any point in time during the lifting operation the crane operator
Cannot directly see the load.

Chains: Chains shall be carefully inspected before use for stretching, wear and surface cuts. A
reduction in diameter of 8% should be considered as a maximum.

Chain blocks: Chain blocks should be treated with care. They shall not be dropped from a height.
The load chain shall not be reeve around the load. They shall not be used to tow vehicles. Always
use them to lift vertically.

Competent Person (Rigging Inspection Personnel) means ; A competent person is a person who
has the knowledge and practical experience of what they are going to examine so as to detect errors,
defects, faults or weaknesses, which it is the purpose of the examination or inspection to discover,
and to assess the importance of any such discovery. Training and assessment refreshing is a must
and there is a thorough regulation in “HSE Training Procedure “.

Containers Containers shall normally be fitted with their own sets of slings suitable for the load
to be lifted. The whole assembly of container and slings shall be marked with its SWL. Loose
materials & articles inside the container should be secured to prevent spurious displacement,

Cradle : a platform or trolley in which workmen are suspended on the side of a building or ship

Flat belt slings: Made of woven fibers, they can be damaged by sharp edges. Sharp edges of load
shall be packed.

55
Heavy Lifting : any lifting which the load is equal or more than 20 tons.

Hoist : A lifting machine, whether worked by mechanical power or not, with a carriage, platform or
cage the movement of which is restricted by a guide or guides, but does not include a lifting
appliance used for the movement of trucks or wagons on a line of rails.

Lifting accessories :
 Textile slings and their components
 Steel wire rope slings and their components
 Chain slings and their components
 Lifting eyelets
 Lifting ear
 Lifting anchor
 Rope eyelets
 Lifting beam
 Lifting forks
 Lifting magnet
 Foundry crane
 Lifting wheel

Hooks: Hooks are normally fitted with a safety catch. If the catch is missing or damaged the hook
should not be used. In certain case, the hook can be mouse with wire and a shackle used.

Jacks: Jacks shall be used on a strong sound footing of sufficient area to distribute the load.
Precautions shall be taken to prevent the jack head from slipping. A load should not be left supported
by jacks, only packing shall be used.

Lifting Appliances : means any lifting machine including cranes used for the purpose of raising,
suspending, Supporting or lowering of persons, goods or materials.A crab, winch, pulley block or
gin wheel used for rising or lowering and a hoist, crane, etc.

Lifting equipment

a) Cranes, hoists and winches - hand or power operated.

b) Ropes, chains and slings of all materials used for lifting purposes.
c) Eyebolts, shackles, pulley blocks and gin wheels.
d) Lifting beams - portable or runway.
e) Specially designed lifting rigs, e.g. for handling of magnets, specialized
equipment included in the experimental rigs etc.
f) Lifts - passenger and goods.
g) Fork lift trucks, power workers, similar devices and attachments used with the
equipment.

Lifting Gear : include all means of attaching a load to a lifting appliance (ropes, slings, chains,
shackles, hooks, link plates, spreader bars, swivels, containers, baskets, etc.).

56
Man Basket : a lift platform that slides onto the tines (forks) meant for hoisting workers. The man
basket has railings and brackets for attaching safety harnesses.

Mobile Crane means : A mobile crane is defined as a crane capable of traveling under its own
power, but not including a crane that travels on a line of rails.

Safe Working Loads (SWL) : The Safe Working Load (SWL) is defined as the maximum
load that can be safely handled by a crane.
Every lifting appliance and piece of lifting gear shall be clearly marked with,
Its SWL as shown on the latest record of examination,
An identifying number or mark either by stamping or tagging.
A lifting appliance or lifting gear shall not be used for any load exceeding its SWL.

Shackles: shackles pins shall be fitted with a safety link to prevent spurious release of the pin nut.
Bolts shall not be used as replacement of missing pins.

Slings: A looped or hanging band, strap, etc. used in raising and lowering a heavy object or for
carrying, supporting, or steadying something. Slings up to ½” diameter is the most common type of
slings used on site. The SWL of a sling depends on the steel wire it is made of. Two wire ropes of
same diameter may be of different SWL. Never use a sling, which is not marked with its SWL.
Properly manufactured slings only are to be used. Spliced slings shall not normally be used for
lifting. Bulldog grips shall not normally be used. If they are used the de-rating of the eye-is 25%.
The strain in the legs-of a multiple sling increases when the angle between the legs increases. The
angle should not be more than 900.

57
 1000 Tons
500 Tons each

1000 Tons
1000 Tons

750 Tons each 750 Tons each

1000 Tons 1000 Tons

>1000 Tons

>1000 Tons 1000 Tons

1200 >1200

1000 Tons 1000 Tons

Thorough examination means detailed visual examination and other means of measure to
ascertain the condition of the piece of lifting gear.
Inspection means a visual inspection to ascertain that the piece of lifting gear is safe for
use.
Work means ; All and any of the works, services and Materials required to be provided
by Contractor for the full and complete realization of the Plant.

58
 7. REFERENCES
OSHA Standards (Occupational Health and Safety Administration) Ed:2007
NIOSH Standards (National Institute of Safety and Health) Ed:2007
B.S (British Standard) Ed:2004
ASME Standards, B30 (American Mechanical) Ed:2003
ILO Standards (International Labor Office) Ed:2003
OGP Standard (The International Association of Oil & Gas producers)

8. Attachments

Attachment 1: Figures
Attachment 2: Checklists
Attachment 3: Lifting equipment register form
Attachment 1: Figures
FIGURE 1; SLINGS (GENERAL)

60
FIGURE 2; PIPE SLINGS

61
FIGURE 3; COMBINATION SLINGS

62
FIGURE 4; HOOKS AND EYEBOLTS

63
Figure 5 below gives the maximum load in the rope and the load on the support when
lifting a load W with a friction figure of 8%.

64
FIGURE 6 ; HOOKS AND EYEBOLTS (CONT)

65
FIGURE7; PLATE LIFTING

66
FIGURE 8 :

67
FIGURE 9

Figure9.1 Self-Propelled MWP

Self-Propelled Articulated
Boom Self-Propelled Scissor

[Figure9.2 Vehicle-Mounted MWP]

Van-mounted Telescopic Boom

68
 [Figure9.3 Mast Climbing Work Platforms]

Note: Safety Barrier omitted for clarity.

[Figure9.4 Man-Riding Skips and Cradles]

69
ATTACHMENT 2 : CHECKLISTS

CRANE /MOTOR VEHICLE INSPECTION CHECKLIST

CONTRCATOR/SUBCONTRACTOR
VEHICLE NO: PMA NO:

TYPR: EXPIRES NO:

MODEL: ROAD TAX EXPIRES NO:

CAPACITY: OTHERS:
NIRC NO: DATE OF INSPECTION:
LICENSE NO:
SIGNAL MAN NAEM: -------------- ----------------
SIGN HSE STAMP
BADGE NO:
CONTRACTORINSPECTORNAME: REINSPECTION ON:

DATE OF INSPECTION: INSPECTION CERT. NO:

NEXT INSPECTION ON: REINSPECTED ON:

INSPECTION CERT. NO: INSPECTION CERT. NO:

ALL CRANE, EXCAVATORS, FORKLIFTS SHALL BE REINSPECTED FOLLOWING AN
ENTRY WHENEVER IT IS TAKEN OFFSITE AFTER EACH WORK DAY.
Y= YES N= NO NA= NOT APPICAABLE
LOAD RATING SHART
SAFE LOAD INDICATOR
OUTRIGGERS
LEAKING HYDROAULICS
BOOM BREAK
BOOM HANDLING DEVICE
HOOK OVER HEIGHT LIMIT SWICH ALARM
HOOK CATCH/MOUSED/”C”
BOOM TELESCOPIC MECHANISM HOLDING
DEVICE
SLEWING BREAK
SLEWING HOLDING DEVICE
SLEWING LOCK
FLY JIB
VISIBLE DAMAGE
VISIBLE CORROSION
VISIBLE CRACKS
SHACKLES WITH S.W.L

70
SLINGS WITH S.W.L
LOCATION FOR CRANE POSITION
GROUN CONDITION CHECKED
OUTREIGGING WITH STEEL PLATE
CRANE BOOM SLING WIRE ROPE CHECKED
HOIST BLOCK CHECKED
WORKING RADIOUS LOAD CAPACITY
CONFIRMED
REMARKS

‫ ٭‬description,e.g,little,etc .
‫ ٭٭‬comments, e.g.descriptionof a rope deformation .

71
 WIRE ROPE INSPECTION CHECKLISTS

Wire rope inspection

Check List

Machine: application:

Type of rope: left hand lay right hand lay

Nominal diameter [ mm]: regular lay langs lay

Tensile strength [N/mm2]: ungalvanized galvanized

Rope length [m]: type of end fitting :

Date of installation: working hours to date:

no. of broken
Diameter/
wires abrasion corrosion -reduction mm/% other
Location on10xd
measured Allowed no.:
‫٭‬ ‫٭‬ eff. of new rope ‫٭٭‬

Final evaluation : Date /signature:

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CHECK LIST (A)

BELOW ARE SOME ITEMS WHICH SHOULD BE CHECKED WHEN CONSIDERING

LIFTING GEAR / MATERIAL HANDLING .

No Description yes no n/a Comments

1 Is the correct color code clearly displayed on
prominent signs around the site?

2 Are suitable quarantine arrangements made for out of

spec. / out of test lifting gear?

3 Is a list of lifting gear & examination results

available?

4 Are correct slinging arrangements being used?

5 Do all crane hooks have safety latches?

6 Are slings marked with a SWL, ID number and color

coded?

7 Are personnel aware of the maximum internal angle

between each leg of a sling and that special
precautions should be taken when lifting with an angle
> 90o.

8 Is the weight of the object satisfactorily known?

9 Are all shackles and eye bolts marked with the SWL,
ID number and color coded?

9 Are all chains and plate clamps marked with the SWL,
ID number and color coded?

10 Are plates being handled correctly?

11 Has the correct examinations / tests been carried out

on the crane?

12 Before a new crane works on site has the certification

of the crane & the driver been checked?

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CHECK LIST (B) :
BELOW ARE SOME ITEMS WHICH SHOULD BE CHECKED WHEN CONSIDERING
CRANE OPERATIONS

No. Description yes no n/a Comments

1 Does the crane have the correct certification?

2 Does the crane operator have the correct

certification? Is he competent? Has he been
tested by Authorities?

3 Are the appropriate weekly checks made and

records kept?

4 Has the crane been load tested and examined

in accordance with the inspection procedures?
Are records OK?

5 Is the lifting tackle properly marked? Are the

records OK?

6 Has the lifting gear been examined in

accordance with the inspection procedures?
Are records OK?

7 Is all lifting tackles correctly color coded?

8 Is the radius/load indicator working correctly?

9 Are there audible signals both inside & outside

the cabin at predetermined radius/load values?

10 Is there a fire extinguisher in the cabin?

11 Is the crane operator aware of any restricted area

i.e. lifting over live process plant or pipelines?

74
MANBASKET Checklist
Item Y N n/a
The basket has been designed with a 5:1 safety factor by a qualified engineer and
welded by a qualified welder.
The suspension rigging system has been designed in such a way as to minimize
tipping of the manbasket
The maximum rated load and maximum capacity is posted on a permanently
affixed plate on the manbasket.
The guardrail designed to enclose the platform is provided and is enclosed from the
toeboard to the mid-rail.
Body harness anchorage provided
The access gate has been designed to open in and is positively prevented from
swinging outward while the manbasket is in use.
The access gate must have a positive locking system to prevent accidental opening
during operation.
The design allows enough headroom for employees to stand upright
There are no rough edges on any manbasket surface.
In addition to hard hats, overhead protection is provided when employees are
exposed to falling objects.
A trial-lift meeting has been attended by the crane or derrick operator, signal
person(s) (if necessary for the lift), employee(s) to be lifted, and the employee
responsible for the task to be performed
Precautions have been taken to protect employees from any special hazards in the
area where the crane and manbasket will be operating; for example, power lines or
areas where the manbasket will be out of the operator’s view.
Special precautions have been taken to protect personnel from electrical hazards.
When the crane with a manbasket is working near electrical lines or devices, the
minimum working clearances shall be at least twice those for material handling
operations.
A manbasket use authorization has been issued dated and properly signed for the
task at hand.
The manbasket and rigging has been proof-tested to 125 percent of the platform
rated capacity.
An unoccupied trial lift loaded to at least the anticipated lift weight has been
performed and hoisted to each location where work is to be performed, or to any point
where employees are expected to enter or exit the platform. NOTE: The trial lift must
be performed each time the crane is moved.
A post trial-lift inspection of the crane has been carried out by a designated
employee.

The loading is less than 50 percent of the crane-rating chart for all work locations.

75
The operator has determined that all systems, controls, and safety devices are
activated and functioning properly and that no interferences exist.
The manbasket has been hoisted a few inches and has been re-inspected after the
trial lift for any deficiencies.
Prior to hoisting personnel, the manbasket has been hoisted a few inches to verify
its hang level.
All hoist ropes are free of kinks.
MANBASKET Checklist
Item Y N n/a
Multipart lines are not twisted around each other.
The hook is centered over the load.
The hoist lines are laying properly on hoist drums and in the sheaves.
All post trial lift defects have been corrected.
The crane-bearing surface has been rechecked and crane re-leveled as required.
Have the crane safety components, dogs, pawls, brakes, etc., have been re-
inspected after the trial lift.
Travel with the crane is not permitted except where all requirements are satisfied
and where not to do so would endanger life
The operator has been advised that the load and boom hoist drum brakes, swing
brakes, and locking devices such as pawls or dogs must be engaged when the
occupied personnel platform is in a stationary working position.
The operator has been advised that the platform must be hoisted in a slow, controlled,
cautious manner with no sudden movement of the crane, derrick or platform.

The operator has been advised that the platform must be hoisted in a slow, controlled,
cautious manner with no sudden movement of the crane, derrick or platform.

Employees have been advised to perform tasks specified in the manbasket authorized
only. NOTE: Only the number of employees needed for the task at hand is
allowed to be hoisted.
Prior to hoisting personnel, the manbasket has been hoisted a few inches to verify
its hang level.
All hoist ropes are free of kinks.

All employees have been advised to keep all body parts inside the platform during
raising. NOTE: This provision does not apply to an occupant of the platform
performing the duties of a signal person.
All employees have been advised that they are not allowed to enter or exit the

platform when it is secured to the structure where the work is to be performed

unless securing to the structure creates an unsafe situation.
All employees have been advised that they are not allowed to exit the platform
before landing.

76
All employees have been advised that taglines must be used unless their use would
create an unsafe condition.
The operator has been advised to remain at the controls at all times while the crane
engine is running and the platform is occupied.
All employees have been advised that platform use must be promptly discontinued
if there is any indication of dangerous weather conditions or other impending danger.

The operator is in constant contact by standard hand signals or voice

communications during operation of crane and manbasket.
All employees have been advised to remain in continuous sight of or in direct
communication with the operator or signal person.

All employees have been advised that the use of a radio is permissible when direct
visual contact is not possible, or where the use of a signal person could create a
greater hazard.

MANBASKET Checklist
Item Y N n/a
All employees occupying the platform have been advised to wear a body belt or
harness system, with the lanyard appropriately attached to the lower load block,
overhaul ball, or structural member within the personnel platform capable of
supporting the fall impact for employees using the anchorage.
All employees have been advised to wear a life vest when working over water.
Employees have been advised to secure materials and tools to prevent
displacement during the lift.
All employees have been advised to load the manbasket evenly and to only carry
tools and materials needed for the task at hand.
The operator, and all employees that will be using the platform, have been advised
that no other object may be lifted on any of the crane load lines while the platform
is suspended.
An audible and visual device has been provided to the personnel in the platform so
that they can signal for assistance in the event of an emergency.
Personnel have been advised to stand firmly on the floor of the platform and to not
sit or climb on the edge of the platform or use planks, ladders, or other devices for
attaining a work position.
If welding is to be performed by employees occupying the platform, the electrode
must be protected from touching the metal components of the platform.

Any needed repairs to the crane or manbasket used only original manufacturer
parts to ensure that the new components are compatible with their original
counterparts.
Care taken to prevent ropes, electrical chords, and hoses from becoming entangled
in the platform when the platform is being moved.

77
Operator aids or interlocks have not been altered, modified, or disabled in any
way.
The crane operator responsible for operating the cranes used for personnel
handling is a thoroughly trained operator and has related experience operating the
subject crane.
All manuals, operating instructions, and load charts provided have been read and
understood by the operating personnel prior to starting the operation.
The operator has ensured that the area surrounding the platform is clear of
personnel and equipment before moving the platform.
Prior to the trial lift at each new location, a pre-lift meeting has been held, and is
also held for any new employee assigned to the manbasket.
All deficiencies discovered in post trial-lift inspection have been corrected.
All employees attending the pre-lift meeting signed the roster for the meeting.
The trial-lift calculation sheet has been completed, signed and dated.
All employees have been advised to keep all body parts inside the platform during
raising. NOTE: This provision does not apply to an occupant of the platform
performing the duties of a signal person.
All employees have been advised that they are not allowed to enter or exit the
platform when it is secured to the structure where the work is to be performed unless
securing to the structure creates an unsafe situation.
All employees have been advised that they are not allowed to exit the platform
before landing.
All employees have been advised that taglines must be used unless their use would
create an unsafe condition.
MANBASKET Checklist

Item Y N n/a
The operator has been advised to remain at the controls at all times while the crane
engine is running and the platform is occupied.
All employees have been advised that platform use must be promptly discontinued
if there is any indication of dangerous weather conditions or other impending danger.

The operator is in constant contact by standard hand signals or voice

communications during operation of crane and manbasket.
All employees have been advised to remain in continuous sight of or in direct
communication with the operator or signal person.

All employees have been advised that the use of a radio is permissible when direct
visual contact is not possible, or where the use of a signal person could create a
greater hazard.
All employees occupying the platform have been advised to wear a body belt or
harness system, with the lanyard appropriately attached to the lower load block,
overhaul ball, or structural member within the personnel platform capable of
supporting the fall impact for employees using the anchorage.
All employees have been advised to wear a life vest when working over water.

78
Employees have been advised to secure materials and tools to prevent
displacement during the lift.
All employees have been advised to load the manbasket evenly and to only carry
tools and materials needed for the task at hand.
The operator, and all employees that will be using the platform, have been advised
that no other object may be lifted on any of the crane load lines while the platform
is suspended.
An audible and visual device has been provided to the personnel in the platform so
that they can signal for assistance in the event of an emergency.
Personnel have been advised to stand firmly on the floor of the platform and to not
sit or climb on the edge of the platform or use planks, ladders, or other devices for
attaining a work position.

79
 Attachment 3: Lifting equipment register form

Lifting Equipment Register Form

Equipment Name (Description):........................................................................................

Serial Number:.................................................................................................................
Name of manufacturer:.....................................................................................................
Subcontractor:.................................................................................................................
Working area:..............................................................................................................................................
Date of first Used: SWL:

Test Date : Test Load:

Defects:

Comments:

Results:
Defective ( Unusable) Repairable Safe

Retest date:
Operator: tester: HSE Supervisor:

Signature: Signature: Signature:

Date: Date: Date:

80
 SUGGESTIONS FOR THE DSC
LIFTING, RIGGING & HEAVY LIFTING OPERATIONS SAFETY PROCEDURE

MANAGER, HSE Department

Dashti Sanat Company

Please consider the following suggestion(s) relative to the POGC Lifting, rigging & heavy lifting operations
safety procedure:

(Signature)

(Date)

(Address)

Contact Telephone Number

81