Lifting Supervisor: Oil & Gas

Oil & Gas

Lifting Supervisor

Offshore Cranes – 4 Days Training Course

Sacha Sarkissians [email protected] +971552580276

www.dnvgl.com

SAFER, SMARTER, GREENER Ungraded

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DNV GL © 2016

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Company Introduction DNV GL is an international certification body and classification society. DNV GL's history dates back to 1864, DNV GL celebrated its 150th anniversary in 2014. DNV GL has More than 15,700 people worldwide.

Organizations: 1. Oil & Gas 2.Maritime 3.Energy 4.Business Assurance 5. Software 6. Healthcare

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Day 1 – Rigging and Slinging 1. COURSE INTRODUCTION 2. THE LAW & STANDARDS 3. DUTIES & RESPONSIBILITIES 4. CLASSIFICATION OF LIFTING EQUIPMENT 5. LIFTING ACCESSORIES TYPES & USE. 6. LIFTING APPLIANCES TYPES & USE. 7. LIFTING EQUIPMENT TYPES & USE. 8. COLOUR CODE SYSTEM. 9. SAFE WORKING LOAD & WORKING LOAD LIMIT. 10. LOAD WEIGHT CALCULATIONS 11. CENTRE OF GRAVITY 12. KINDS OF HITCHES 13. ANGLES OF LIFTING 14. MULTI-LEG SLINGS RATING 15. GOOD & BAD RIGGING PRACTICES. 16. LIFTING ACCESSORIES INSPECTION 17. HAND SIGNALS 18. VIDEO ILLUSTRATION & ASSIGNMENT (DAY 1) Ungraded

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Day 2 – Offshore Cranes 1.

OFFSHORE CRANES TYPES

2.

OPERATION MANUAL & LOG BOOK

3.

PROXIMITY HAZARDS

4.

WORKING WITH CRANE

5.

OFFSHORE CRANE SETUP

6.

BAD LIFTING PRACTICES

7.

LOAD RATING CHART PEDESTAL CRANES

8.

RATED CAPACITY INDICATOR (SLI)

9.

TANDEM LIFTING

10. VIDEO ILLUSTRATION 11. CASE STUDY 12. ASSIGNMENT DAY-2

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Day 3 – Lifting Plan 1.

RISK ASSESSMENT

2.

LIFTING PLAN CLASSIFICATION

3.

LIFTING PLAN CONTENTS

4.

METHOD STATEMENTS

5.

LIFTING DATA TABLE

6.

PRACTICAL TRAINING & ASSIGNMENT DAY-3

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Day 4 – Examination 1.

WRITTEN EXAM

2.

WRITTEN EXAM (Lifting Plan Exam)

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1 Course Introduction

Chapter 1 Course Introduction

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1 Course Introduction – Pre Qualifications 1. Who should attend this course? A.

This Course is suitable for Supervisors and Managers with responsibility for lifting operations.

2. Entry Requirements? A. Be at least 32 years of age and above. B. Have relevant oil & gas offshore and onshore lifting related experience of not less than 10 years in the same area of application with 5 years in a similar position. C. Have adequate training and hands on professional experience and be competent to act as a Lifting Supervisor for lifting equipment. D. Shall be able to supervise and execute critical lifting in oil & gas companies. E.

Have focus on HSE priorities and lead a team of engineers for Safe Lifting Practices across different locations of the organization.

F.

Familiar with international standard related to Lifting engineering practices with sufficient knowledge in interpretation and to bring excellence in Change management.

G.

Lifting Supervisor shall be trained and be assessed every 3 years through theoretical examinations by suitably trained / certified and qualified assessor approved by ADMA-OPCO.

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1 Course Introduction – Course Schedule

Day 1 Course Timing: 8:00 AM to 4:00 PM Tea Break: 10:00 AM to 10:15 AM Lunch Break: 12:00 PM to 12:30 PM Tea Break: 2:30 PM to 2:45 PM

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1 Course Introduction – Course Schedule

Day 2 Course Timing: 8:00 AM to 4:00 PM Tea Break: 10:00 AM to 10:15 AM Lunch Break: 12:00 PM to 12:30 PM Tea Break: 2:30 PM to 2:45 PM

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1 Course Introduction – Course Schedule

Day 3 Course Timing: 8:00 AM to 4:00 PM Tea Break: 10:00 AM to 10:15 AM Lunch Break: 12:00 PM to 12:30 PM Tea Break: 2:30 PM to 2:45 PM

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1 Course Introduction – Course Schedule

Day 4 Course Timing: 8:00 AM to 4:00 PM Tea Break: 10:00 AM to 10:15 AM Lunch Break: 12:00 PM to 12:30 PM Exam: 2:30 PM to 4 PM

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2 The Law and Regulations 1.

UAE Federal Ministry, Decree 32 Article 20-1982.

2.

Environmental Health & Safety Regulation CoP-034 of February 2012

3.

European Directive.

4.

PUWER 1998: ACOP and guidance.

5.

LOLER 1998: Open learning guidance.

6.

ADMA-OPCO Code of Practice CP-113.

7.

PRO-141 (Procedure for Operation, Maintenance & inspection of Loose Lifting Equipment.

8.

PRO-142 (Procedure for Operation, Maintenance & inspection of Fixed Lifting Equipment.

9.

SP-1104 Loadout, Transportation and Installation of Offshore Structure.

10. GLND 0027 Guidelines for Marine Lifting & Lowering Operations. Ungraded

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2 The Law and Regulations – UAE LAW

UAE Federal Ministry, Decree 32 Article 20-1982  Cranes & Lifts for men & Materials shall be of sound construction and manufacture, regularly maintained and checked by a qualified technician at least every 6 or 12 months.  The areas where lifts are fitted shall be fenced in such a way as to prevent access or egress whilst moving, doors should not be opened whilst in motion.  Chain, Ropes, Wire Ropes & other lifting equipment shall be continuously & completely maintained and checked by a competent technician at least every 6 months. Ungraded

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2 The Law and Regulations – UAE LAW  The maximum capacity of machine of lift shall be displayed in a prominent position.  An employee may not be asked to carry loads above his capacity, and in any case no load shall exceed 50kg per man and 20 kg per woman and where possible mechanical lifting shall be used.

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2 The Law and Regulations – AD EHSMS RF

Environmental Health & Safety Regulation CoP-034 of February 2012  This Code of Practice (CoP) applies to all employers within the Emirate of Abu Dhabi. this CoP is designated to incorporate requirements set by Abu Dhabi EHS Center and Sector Regulatory Authorized in the emirates of Abu Dhabi.  This CoP applies to the use of all type of lifting equipment and lifting accessories in accordance with the definitions laid out in this section.

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2 The Law and Regulations – European Directive

European Directive  A European Directive is not a law. It is an instruction to the governments of member states of the EU to introduce national laws in line with the requirements set out in the European Directive and withdraw any existing legislation that may be contrary to this.  In the UK this is done by introducing regulations made under the Health and Safety at Work etc Act 1974 (HASAW) or under the European Communities Act 1972.

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2 The Law and Regulations – PUWER

PUWER 1998: ACOP and guidance  Keep work equipment maintained in a safe condition and in good working order.  Keep a record of maintenance for work equipment.  Have regular inspections of the equipment to ensure it stays in a safe condition.  Make sure the equipment conforms to all local legislations.

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2 The Law and Regulations – LOLER

LOLER 1998: Open learning guidance  LOLER takes a different approach referring only to a lifting operation and any equipment used in that operation is considered to be lifting equipment.  Make sure the lifting equipment and any attachments is strong enough for each load and that it has adequate stability for its intended use.  Use a greater factor of safety when using lifting equipment to lift persons and only use equipment which is designed for lifting persons.  Install and position lifting equipment in such a way that you reduce the risk of the load from striking personnel, the load drifting, falling or being released. Ungraded

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2 The Law and Regulations – LOLER  Make sure all relevant information is marked on the lifting equipment including the SWL in any configuration. The marking of lifting equipment which is designed for lifting persons should be so marked, lifting equipment that is not designed for lifting persons but could be used in error should be marked that it is not designed for this purpose.  Ensure that every lifting operation involving lifting equipment is planned by a competent person, appropriately supervised and carried out in a safe manner. The person planning the operation should have adequate practical and theoretical knowledge and have experience of planning lifting operations.

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2 The Law and Regulations – LOLER  Ensure that every lifting operation involving lifting equipment is planned by a competent person, appropriately supervised and carried out in a safe manner. The person planning the operation should have adequate practical and theoretical knowledge and have experience of planning lifting operations.  Lifting equipment must be thoroughly examined. A. In accordance with an examination scheme. B. After an accident. C. After repair.  Report defects to the owner of the equipment and in the case of defects which could become a danger to persons send a report to the relevant authorities.

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Duties and Responsibilities – Appointed Person

Appointed Person (BS 7121)  To ensure the implementation of the safe system of work, one person should be appointed to have overall control of the lifting operation to act on behalf of the management of the organization requiring the load to be moved, The appointed person does not remove any legal responsibility from the management but enables them to use his expertise the better to fulfil their responsibilities. The person appointed may have other duties and need not be an employee of the Employing Organization. The appointed person should have adequate training and experience to enable these duties to be carried out competently.

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Duties and Responsibilities – Appointed Person The Appointed Person has operational control of the lift and:

 Is designated as being in charge of planning, coordinating, controlling and executing the lift.  Selecting the correct crane and accessories for the specific task;  Prepare the lift plan and ensure the required controls are in place;  Ensures that the lifting equipment is maintained, examined and appropriate for use;  Checks that load integrity and stability are satisfactory;  Ensures that people involved are competent for performing their task, aware of the task and procedures to be followed, and aware of their responsibilities;  Ensure competent supervisor available should the Appointed Person delegate his duties to others; Ungraded

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Duties and Responsibilities – Appointed Person

 Ensure all necessary test certificates and other documents are available;  Ensure all other statutory requirements and any necessary work permits are in place;  Identify all hazards and restricted areas;  Emergency Procedures in case of damage or impairment to the crane during operation, and for safe recovery of the crane to a holding location on the installation;  Ensuring that the person directing crane movements (Signaller / Banksman) is readily identifiable to the crane operator by wearing high visibility clothing or distinguishing markings;  Ensuring that the workplace is provided with adequate lighting for night lifting;  Briefs people involved in or affected by the lift; Ungraded

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Duties and Responsibilities – Appointed Person

 Ensures the lift is carried out following the plan. Suspends the lift if changes or conditions (eg, wind) occur that would cause a deviation from the plan;  Monitors the performance of all involved personnel to ensure that adequate standards of performance are maintained;  Manages any special issues such as language barriers and new/inexperienced staff;  Checks that there is no deviation from standards for routine lifts;  Shall allow for concurrent or simultaneous operations that may affect or be affected by the lift, eg, helicopter operations, ballast control, other cranes.

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Duties and Responsibilities – Appointed Person

NOTE: 1.

The Appointed person can delegate his duties to competent personnel however the responsibility is still with the Appointed Person.

2. The Appointed person has the authority to stop operations where danger is likely to arise if operations continue.

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Duties and Responsibilities – Rigger & Slinger

Rigger & Slinger (BS 7121)  The Rigger is responsible for attaching and detaching the load to and from the crane.  The Rigger is also responsible for the selection of the correct lifting arrangement in accordance with planned lifting operations and to check them prior to the use.  The directing and movement of the crane/load is initiated by the Rigger / slinger using the designated signaling method, should there be more than one Rigger required then only one should have the responsibility at any one time depending on the position and movement of the crane/load.  Trained to use man-baskets and conversant with the relevant lifting procedures.  Physically, he must be capable of handling lifting gear and equipment.

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Duties and Responsibilities – Rigger & Slinger

 Ensure at all times that the load is under complete control by the use of tag lines, or whatever assistance that is deemed necessary.  Able to establish weights and the effect of the centre of gravity, and to balance loads and judge distances, heights and clearances.  Ensure that no load is to be lifted where the weight is not stated or unknown.  Check that the lifting equipment being used is in good condition, certified for use, correctly colour coded, and of sufficient capacity to carry out the lift.  Be aware of any obstructions within the crane radius and working area.  Ensure that crane hook is position above load centre signalling to the crane operator.

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Duties and Responsibilities – Rigger & Slinger

 Ensure that escape route is identified.  Check that no personnel are beneath the load whilst lifting is in progress.  Ensure all hands are free of lifting tackle and stand clear before the load strain is taken.  Clearly indicate to the crane operator where the load has to be moved to or placed and, where possible, he shall follow each load to its destination.  Ensure that no personnel standing on the load or between two loads, especially if one Load will be lifted and repositioned.  Warn other personnel in the area of the movement of the load.  Observe and note other activities within the crane‘s operating area to avoid the development of any unforeseen hazards. Ungraded

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Duties and Responsibilities – Rigger & Slinger

 Stop the lifting operation if anything out of the ordinary occurs and check that it is safe to continue the operation, solely direct the lifting and loading activities and operations.  Rigger shall be assessed for working at night by an Approved Training Company.  Company and clearly mentioned in the Assessment Certificate.

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Duties and Responsibilities – Banksman / Signaller

Banksman / Signaller (BS 7121)  The Signaler acts as a second party responsible for directing a crane when the Rigger is out of vision. The Signaler has similar responsibilities to the Rigger / Slinger.  Banksman shall be assessed for working at night by an ADMA Approved Training Company and clearly mentioned in the Assessment Certificate.

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Duties and Responsibilities – Crane Operator

Crane Operator (BS 7121)  The crane operator should be responsible for correct operation of the crane in accordance with the manufacturer’s instructions and the safe system of work and should at any time respond to the signaller’s signals. The crane operator should also undertake other duties (including routine crane lubrication, daily and periodic maintenance checks of the crane) and should assist with the change out of ropes and hook blocks and procedures recommended by the crane manufacturer and operating company, and authorized by the appointed person.  All crane operators (including fully qualified) should be assessed every 2 years through practical and theoretical examinations by approved trained and qualified training company and assessors.

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Duties and Responsibilities – Lifting Supervisor

Lifting Supervisor (BS 7121)  Lifting Supervisor is authorized to direct and supervise the lifting operation, ensuring that these are carried out in accordance with the method statement.  To be competent and suitably trained and should have sufficient experience and authority to carry out all relevant duties.  Fully familiar with the duties of all persons involved in the lifting operation.  Able to assess danger to the lifting operation from changed circumstances on site, and to call a halt to the operation if the risk becomes unacceptable, so that the appointed person can be referred to for further instructions if necessary.  Ensure that the accurate weights, radius, heights, etc… are established.  Ensure suitable lifting machines and lifting gears are provided.

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Duties and Responsibilities – Lifting Supervisor

Lifting Supervisor (BS 7121) Note: The appointed person may decide to undertake the duties of the lifting supervisor or to delegate these to another person with appropriate expertise for the lifting operation.

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4

Classification of Lifting Equipment

Lifting Appliances * Cranes e.g. Pedestal, Mobile, E.O.T. “Overhead Crane” etc.

Lifting Accessories ** Wire Ropes (Davits, Elevators, Man Riding Winches etc)

Lifted Equipment *** CCU’s e.g. Containers, Cargo Basket, Waste Skips, Skids...etc

Life Boat / Life Raft Davits Davit Blocks & Associated Equipment

Wire Rope Slings Chain Slings

Drum Racks / Pipe Racks Flexible Bulk Containers

Forklift Trucks Pallet Stackers Pallet Trucks Personnel & Goods Lifts Suspended Cradles Powered Hoists (Pneumatic & Electric)

Hooks & Fittings Webbing Slings Shackles Eye Bolts Rigging Screws (Turn Buckles) Open Wedge Sockets

Frames Cargo Net Pallets

Manual Hoists (Chain Blocks, Lever Hoists) Jaw Winches (Tirfors) Beam Trolleys Beam Clamps Runway Beams Fabricated Pad-eyes & Clamps Sheave Blocks Crane Hook Blocks Hydraulic Rams & Jacks Winch (Pneumatic, Man Riding, Manual, Davit) Mobile Work Platforms (Man-Lift)

Rings

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Swivels Links Plate Clamps Lifting Beams Lifting Harnesses

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Lifting Accessories Types & Use

Lifting Accessories (Loose Gear):  Any Device that is used or designed to be used directly or indirectly to connect a load to a Lifting Appliance and does not form part of the load. (Wire rope sling, Webbing sling, Chain sling, Shackle, Eyebolts, Clamp, Spreader Beam, ………)

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Lifting Accessories Types & Use – Wire Ropes  Wire Rope Construction

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Construction

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Construction

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Lay or Pitch

THE PITCH IS THE NECESSARY ROPE LENGTH FOR THE STRAND TO COMPLETE ONE ROTATION AROUND THE CORE. IT IS ALSO CALL LAY LENGTH.

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Lay (Z Lay and S Lay)

 Direction of Lay in Stranded Wire Ropes: When the wires in the strand turn in the same direction as the strand in the rope the wires will appear to run along the rope in parallel lines, this is known as Lang’s Lay rope. If the wires in the strand turn in the opposite direction as the strand in the rope the wires appear to run across the rope at an angle, this is known as Ordinary Lay rope, Figure 10 shows a short section of Lang’s Lay rope and a similar piece of Ordinary Lay.

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Lifting Accessories Types & Use – Wire Ropes Lang’s Lay and Ordinary Lay Ropes

 Using the designations given in the BS EN 12385 series of standards a right hand ordinary lay rope is referred to as sZ lay, a left hand ordinary lay rope as zS lay, a right hand Lang’s lay rope as zZ lay and a left hand Lang’s lay rope is referred to as sS lay.

Lang’s Lay

Ordinary Lay

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Measurement

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Measurement

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Inspection

• ID, SWL, Length and Diameter • Third Party Inspection Certificate and appropriate color code. • Kinks and Wear in rope • Reduction in diameter and increase in length. • Lubrication and internal condition. • Broken wire (Maximum 5% in any length equal to 10 times the diameter) • One broken Wire near the Fittings. • Condition of splices and ferrule secured eyes etc. • Corrosion and chemical attack.  increase in diameter in wire rope which is caused by internal corrosion  Checking for internal broken wires by “listening” while bending the wire back and forth. Ungraded

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Defects

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Defects

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Defects

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Lifting Accessories Types & Use – Wire Ropes Wire Rope Defects

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Lifting Accessories Types & Use – Webbing Sling Webbing Slings

Flat Webbing Sling:  flexible sling consisting of a sewn webbing component, with or without fittings for attaching loads to the hook of a crane or other lifting machine.  NOTE: Minimum Factor of Safety shall not be less that 7:1. Round Slings: Endless flexible sling consisting of loadbearing core of yarn, completely enclosed in a woven cover, with or without fittings. NOTE: Round slings shall not be used for any offshore activity. Ungraded

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Lifting Accessories Types & Use – Webbing Sling Webbing Slings Textile slings are manufactured from three man-made fibers:

• Polyamide (nylon): immune to the effects of alkalis, but is attacked by acids • Polyester: resistant to acids but damaged by alkalis • Polypropylene: effected by acids or alkalis but is damaged by solvents, tars, paints etc.

Ungraded

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Lifting Accessories Types & Use – Webbing Sling Webbing Sling Inspection

 Synthetic webbing slings must be removed from service if any of the following defects were found: • Cuts, gouges, abraded spots. • Chemical damage or excessive exposure to sunlight. • Seriously worn surface fibers or yarns. • Knots in any part of the sling. • Considerable, filament or fiber breakage along the line where adjacent strands meet. • Particles of broken filament or fibers inside the rope between the strands. • Excessive pitting or corrosion, or cracked, distorted or broken fittings. • Any other visible damage that causes doubt as to the strength of the sling. Ungraded

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Lifting Accessories Types & Use – Webbing Sling Webbing Sling Marking

 the working load limit, in straight lift.  the material of the webbing, i.e. polyester, polyamide, polypropylene.  grade of fitting, nominal length in m and the traceability code.  the manufacturer’s name, symbol, trade mark or other unambiguous identification !and, where applicable, the name and address of the authorized representative.  the number and relevant Part of this European Standard.  NOTE: Marking this European Standard number on or in relation to a product represents a manufacturer’s declaration of conformity, i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of the standard, Such a declaration is not to be confused with third-party certification of conformity. Ungraded

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Lifting Accessories Types & Use – Webbing Sling Webbing Sling Defects

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Lifting Accessories Types & Use – Webbing Sling Webbing Sling Defects

Ungraded

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Lifting Accessories Types & Use – Shackles Shackles

 Dee shackles are generally intended for joining two items in a straight line.  Bow shackles are designed to enable three or more items to be joined.  Bow shackles are usually when it is necessary to connect a number of slings to hook of a lifting appliance.

Ungraded

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Lifting Accessories Types & Use – Shackles Bow Shackles

Nut & Safety Pin Types shackle

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Screw Pin Type shackle

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Lifting Accessories Types & Use – Shackles Dee Shackles

Nut & Safety Pin Type

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Screw Pin Type

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Lifting Accessories Types & Use – Shackles Wide Body Shackles

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Lifting Accessories Types & Use – Shackles Shackle Marking Manufacture’s name Size of body

Working Load Limit

Grade

Identification Number

Ungraded

60

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Lifting Accessories Types & Use – Shackles Shackle Inspection



Absence of capacity or identifying marks



Bent or distorted pin and/or body



Nicks, gouges or cracks



Heat or chemical damage



Body spread



Reduction in diameter of pin and/or body by more than 8%

wear pin Distortion

spread shoulder flush

Ungraded

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Lifting Accessories Types & Use – Shackles Defected Shackles

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts There are three types of eyebolt:  Dynamo Eyebolt.  Collar Eyebolt.  Eyebolt with link.

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts

Dynamo Eyebolt:  

Large eye sitting on a small collar but not blended into that collar. suitable only where a truly axial load is guaranteed.

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts

Collar Eyebolt:   

Has a smaller eye than the dynamo and blended to the collar in one plane. The eye is not large enough to accept a hook so a shackle MUST be used. Suitable for most general duties (A collar eyebolt fitted with a link is not the same as an eyebolt with link and must not be treated as such)

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts

Eyebolt with link: 

The SWL is greater than the collar eyebolt when used in the same scenario.



Suitable for all general purpose application.

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts Marking Quality Marking

Thread Size

Working Load Limit

EB1600 Identification Number

Ungraded

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Lifting Accessories Types & Use – Eye Bolts Eye Bolts Inspection

Check marking of WLL

Check inside of eye for wear

Check for deformation

Check for cracking

Check thread centre is aligned with centre of eye

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Check thread for corrosion

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Lifting Accessories Types & Use – Eye Bolts Defected Eye Bolts

Ungraded

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Lifting Accessories Types & Use – Chain Slings Chain Slings

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Lifting Accessories Types & Use – Chain Slings Chain Slings Inspection

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Lifting Accessories Types & Use – Chain Slings Chain Slings Inspection

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Lifting Accessories Types & Use – Chain Slings Chain Slings Inspection

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Lifting Accessories Types & Use – Chain Slings Chain Slings Defects

Ungraded

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Lifting Accessories Types & Use – Hooks

Hooks

Eye Hook with Safety Latch

Clevis Hook Ungraded

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Swivel Hook with Self Locking

Shank Hook

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Lifting Accessories Types & Use – Hooks

Hook Inspection Hooks must be inspected by a competent person and removed from service when any of the following conditions exist:

•

Cracks, nicks or gouges.

•

Twist exceeding 10° from plane of unbent hook.

•

Latch engagement, damage or malfunction.

•

Throat opening exceeding 15%.

•

Wear exceeding 8% of original dimension.

•

Damage from heat.

•

Unauthorized repairs.

Ungraded

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Lifting Accessories Types & Use – Hooks

Hook Inspection

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Lifting Appliances Types & Use

Lifting Appliances (Lifting Machine): Any Mechanical Device capable of raising or lowering a load. (Cranes, Forklift, Winches, ………..)

Maximum Periods Between Thorough Examinations 12 months Ungraded

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Lifted Equipment Types & Use

Lifted Equipment: Any Device that is used to suspend the load.

Lifting Equipment: Any Device that is used to suspend the load. Comprises of Lifting Appliances, Lifting Accessories and Lifted Equipment.

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Colour Code System

 Loose Lifting Equipment shall be inspected and certified by competent person every 6 months as per article 20 of Ministerial Order No. 32 of 1982 and Colour Codes as follows: Pestle Orange – RAL 2003

Jan 2014, 2016, 2018

Grass Green – RAL 6010

July 2014, 2016, 2018

Traffic White – RAL 9016

Jan 2015, 2017, 2019

Signal Blue – RAL 5005

July 2015, 2017, 2019

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Safe Working Load and Working Load Limit

S.W.L – Safe Working Load: Maximum load as assessed by a competent person which an item of lifting equipment may raise, lower or suspend under particular service conditions. The SWL as determined by the Competent Person must NEVER be exceeded.

W.L.L – Working Load Limit: Maximum load that an item of lifting equipment is designed to raise lower or suspend. The WLL as determined by the manufacture must NEVER be exceeded. Mode Factor: factor applied to the WLL of 1 leg sling by taking into account the geometry of the slinging (number and angles of the legs) and the consequence of bending some components.

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10 Load Weight Calculations  Weight can be calculated by knowing the volume and specific weight of the material of the load.  Weight can be measured using a calibrated load cell/ weigh bridge.  Weight can be measured by ASLI of a crane.  Weight can be found from the manifest or shipping documents.  Weight can be found from suppliers documents.  Weight Can be known from Approved Third Party Inspection Certificate. Ungraded

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10 Load Weight Calculations  Convert to standard Shapes:

cylinder = estimated weight

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10 Load Weight Calculations  Formulas:

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10 Load Weight Calculations  Specific Weight of Materials:

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10 Load Weight Calculations  Conversion Factors:  Weight 1 metric tonne = 1000 kg 1 metric tonne = 2204.622 lb 1 long ton (UK) = 2240 lb 1 short ton (US) = 2000 lb  Distance 1 meter 1 meter 1 foot

= 100 cm = 3.28 feet = 0.3048 m

 Force 1 kN

= 101.97 kgf

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= 1.016 tonne = 0.907 tonne

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11 Centre of Gravity C of G – Center of Gravity  Center of gravity is the point where the total weight of the body may be regarded as acting.  Another way of saying this is that the C of G is the point about which the parts of a body exactly balance each other.  With a regularly shaped load the C of G is at the mid point in each direction plane. For complex shapes, it may be necessary to estimate the center of gravity of various parts and then combine them to get a center of gravity as a whole.

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11 Centre of Gravity C of G – Center of Gravity  Center of balance of load can be determined by mathematical calculations while at the design stage or with measurements.  The most convenient practical approach is trial and error method.

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11 Centre of Gravity Center of Gravity - Calculations

 In the above figure if weights of three parts A, B & C are WA, WB, & WC respectively, then  (WA + WB + WC) X = WA YA + WB YB + WC YC  From the above we can resolve value of ‘X’

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12 Kind of Hitches Kind of Hitches:  Vertical Hitch  Basket Hitch  Choker Hitch

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Vertical

Vertical Basket

Choker

12 Kind of Hitches

Vertical Hitch 

100 % of SWL marked on sling can be utilized to lift the load. Sling should be making a 90° to the surface of the load. Sling in absolute vertical position.



Practically to be on a safe side only 75% of the SWL is considered while doing critical and heavy lifts.



Mode Factor = 1 x SWL of sling

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12 Kind of Hitches Vertical Basket Hitch 

200 % of SWL marked on sling can be utilized to lift the load. Both ends of sling should be vertical. Diameter of Load should be 18 times or more, than the diameter of sling



Mode factor = 2 x SWL of sling

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12 Kind of Hitches Basket Hitch with an angle 

SWL depends on the load angle factor of sling.



Higher the sling angle to the horizontal, the better. Lower the sling angle to horizontal, lesser the capacity.



Mode factor for 45º horizontal angle = 1.4 x SWL of sling

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12 Kind of Hitches 

Choke Hitch



80 % of SWL marked on sling can be utilized to lift the load.



The more you beat down the choke lesser the capacity. Tension increases on the choke point.



Mode factor: 0.8 x SWL of sling

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13 Angles of Lifting 

THE SLING ANGLE (VERTICAL ANGLE) BETWEEN 2 SLINGS SHALL NOT BE LARGER THAN 120º



RECOMMENDED SLING (VERTICAL) ANGLES ARE BETWEEN 0-90 º

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13 Angles of Lifting  Example:

Horizontal Angle

Angularity Factor (AF)

 A 5 ton load has to be lifted with a 2-leg bridle sling.

90

1.000

85

1.003

The horizontal sling angle is 50¾, the slings legs have

80

1.015

75

1.035

70

1.064

65

1.103

60

1.154

55

1.220

50

1.305

45

1.414

40

1.555

35

1.743

30

2.000

table and select the rope

(25)

2.366

(20)

2.924

size required.

(15)

3.863

(10)

5.759

equal length, and the centre of gravity is in the centre of the load. Solution to find wire rope size: 3.26 t is the VERTICAL capacity required for each leg. Look up the

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14 Multi Leg Sling Ratings DETERMINATION OF CAPACITY – 2-LEG SLING AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS SWL OF THE 2-LEG SLING IS DETERMINED BY THE FOLLOWING:

SWL OF THE 2-LEG = 1.4 x WLL (OF SINGLE VERTICAL LEG)

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14 Multi Leg Sling Ratings DETERMINATION OF CAPACITY – 3 - LEG SLING

 AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS

 LOAD MAY BE SUPPORTED BY ONLY 2 LEGS WHILE THE 3RD ONE BALANCES IT ONLY.  THEREFORE SWL OF THE 3-LEG SLING IS DETERMINED BY THE FOLLOWING:  SWL OF THE 3-LEG = 2.1 x WLL (OF SINGLE VERTICAL LEG

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14 Multi Leg Sling Ratings DETERMINATION OF CAPACITY – 4 - LEG SLING

 AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS

 LOAD MAY BE SUPPORTED BY ONLY 3 LEGS WHILE THE 4RD ONE BALANCES IT ONLY.  THEREFORE SWL OF THE 3-LEG SLING IS DETERMINED BY THE FOLLOWING:  SWL OF THE 3-LEG = 2.1 x WLL (OF SINGLE VERTICAL LEG

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15 Good and Bad Practice

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17 Video

Chapter 17 Video

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End Of Day 1

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Day 2 – Offshore Cranes 1.

OFFSHORE CRANES TYPES

2.

OPERATION MANUAL & LOG BOOK

3.

PROXIMITY HAZARDS

4.

WORKING WITH CRANE

5.

BAD LIFTING PRACTICES

6.

LOAD RATING CHART PEDESTAL CRANES

7.

RATED CAPACITY INDICATOR (SLI)

8.

TANDEM LIFTING

9.

VIDEO ILLUSTRATION

10. CASE STUDY 11. ASSIGNMENT DAY-2

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1 Offshore Crane Types

Chapter 1 Offshore Crane Types

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Offshore Crane Types Offshore Pedestal Crane on a Floating Vessel / Barge

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Offshore Crane Types Offshore Pedestal Crane on a Floating Vessel / Barge

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Offshore Crane Types Offshore Pedestal Crane on a Fixed Platform / Jack up Barge

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Offshore Crane Types Sheerleg Floating Crane Barge

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Offshore Crane Types Crawler Crane Mounted on a Floating Vessel

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Offshore Crane Types Knuckle Boom Subsea Crane

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Offshore Crane Types Offshore Pedestal Telescopic Crane

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Offshore Crane Types Offshore Pedestal Box Type Boom Crane

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Offshore Crane Types Offshore Crane Components

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2 Operators Manual and Log Book

Chapter 2 Operators Manual and Log Book

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Operators Manual and Log Book

Importance of Cranes Manual ??  Crane manufacturer provides, with a operating manual and log book with crane. This operating manual comprises of all fundamental information concerned with crane operation like basic specifications, load curves, recommended practices, safety and operating guidelines.  This manual also comprises about the standards which were followed during crane production .Its essential for the operator while operating and purchasing the crane to know about the standards on which crane is manufactured and operate, the reason is that in developed countries their regulatory authorities have specified certain standards, if some machine don’t operate within those standards then it is not allowable to operate the machine in country. Ungraded

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Operators Manual and Log Book

Importance of Operators Log Book ??  It is standard practice of the crane manufacturer to provide a log book with crane manual .This log book is aimed at maintaining the records related to crane like maintenance schedule ,operating hours , oil change and other important information which is found feasible by crane supervisor to maintain for future reference .  With each day /operation entry it is verified and signed by operator, supervisor and in case of repair by the repairman himself. Log book record, need to be maintained throughout crane life.

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3 Proximity Hazards

Chapter 3 Proximity Hazards

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Positions of people within the lifting operation area.  Helicopter activities on crane operations.  Environmental conditions  Dynamic forces on loads  Lifting dangerous goods  Blind lifts  Proximity hazards  Overloading of lifting equipment  Lifting loads over live plant Ungraded

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Positions of people within the lifting operation area.

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Helicopter activities on crane operations.

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Environmental conditions

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Dynamic forces on loads

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Lifting dangerous goods

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Blind lifts

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Proximity hazards

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Proximity hazards

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Overloading of lifting equipment

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Proximity Hazards

Typical Hazards Working with Offshore Cranes  Lifting loads over live plant

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4 Working With Cranes

Chapter 4 Working With Cranes

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Working With Cranes

Pre- Use Checks  The Pre-use Inspection will be performed prior to crane use (typically daily), and then as the Qualified Operator deems necessary during the day for extended operations. This inspection will be performed by a Qualified Operator, and it will apply to all cranes, regardless of usage category.

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Working With Cranes

Pre- Use Checks

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Working With Cranes

Pre- Use Checks

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Working With Cranes

Pre- Use Checks

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5 Offshore Crane Setup

Chapter 5 Offshore Crane Setup

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Offshore Crane Set up

Offshore Crane Set up  Ballasting the Vessel / Barge.  Suitability of the counter weight of the Crane.  Availability of the Operators Logbook.  Availability of an approved Lifting Plan.  Availability of all lifting equipment certifications with valid color code.  Availability of all training certificates for the people in charge.

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Offshore Crane Set up

Crawler crane set up onboard floating vessel / Barge  Ballasting of the Vessel / Barge.  Suitability of the counter weight of the Crane.  Crane Manufacture approval for such lifting operations.  De-rated Load Chart by the Manufacture.  Vessel Class Approval for the suitability of the location which the Crawler Crane will be placed.  Crawler crane to be lashed at all times.  Pick and Carry in prohibited onboard Floating vessel unless approved by the Crane Manufacture and Vessel / Barge Classification scociaty. Ungraded

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6 Bad Lifting Practice

Chapter 6 Bad Lifting Practice

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Bad Lifting Practice

Bad Lifting Practice Load Not Balanced.

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Bad Lifting Practice

Standing under the load.

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Bad Lifting Practice

Standing under the load.

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Bad Lifting Practice

Incorrect method of lifting

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Incorrect Installation

7 Load Rating Chart Pedestal Crane

Chapter 7 Load Rating Chart Pedestal Crane

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Load Rating Chart Pedestal Crane

Load Rating chart  Crane Duty Chart specifying the duties of the crane for the permitted operating conditions should be maintained and located conspicuously in the cabin.  “Hook load” is defined as the load being lifted plus the weight of the slings and rigging. Hook load may or may not include the weight of the hook block and wire rope. This can be determined from the crane’s load rating chart. Examples of ways to determine loads are: Weight indicators, scales, and shore base weighing.  All Load Charts shall be original manufacture load chart and stamped by the Classification society.  De-rated Load Charts are only allowed to be produced by Crane Manufacture.

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Load Rating Chart Pedestal Crane

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Load Rating Chart Pedestal Crane

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Load Rating Chart Pedestal Crane

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Load Rating Chart Pedestal Crane

Knuckle Boom Pedestal Crane

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8 Rated Capacity Indicator (SLI)

Chapter 8 Rated Capacity Indicator (SLI)

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Rated Capacity Indicator (SLI)

Safe Load Indicator or Rated Capacity Indicator  A device which when fitted to a crane gives, within certain specified tolerance limits, a warning of the approach to the safe working load of the crane, and a further warning when the safe working load has been exceeded.  Warning of approach to SWL: The ASLI shall give a clear and continuous warning of approach to SWL. The warning shall commence at not less than 90 % of the SWL and at not more than 97.5 % of the SWL. The approach to SWL warning shall continue to function until the percentage of the load to the SWL falls to some value which is less than the value at which the warning was initiated.

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Rated Capacity Indicator (SLI)

 Warning of overload: The ASLI shall give a clear and continuous warning of overload. The warning shall commence at not less than 102.5 % of the SWL and at not more than 110 % of the SWL. The overload warning shall continue to function until the percentage of the load to the SWL falls to some value which is less.  As per The UAE Law AD EHSMS RF Cop 34 any Crane with a SWL of 1 Tonne or more shall be fitted with a Safe Load Indicator.

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Rated Capacity Indicator (SLI)

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Rated Capacity Indicator (SLI)

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9 Tandem Lifting

Chapter 9 Tandem Lifting

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Tandem Lifting

 Lifts involving two or more cranes are complex operations requiring considerable skill and planning. As a result, multiple crane lifts (or tandem lifts) must be planned and carried out under a competent person's supervision, there are some rules and regulations which we can follow when it comes to Tandem Lifts such as GLND 0027 Rev10 and ADMA SP-1104, important factors to be considered during tandem lift: 1. For a 2-hook lift (hooks on one or two cranes on the same vessel) the individual gross weight at each hook shall be multiplied by the following factors, to account for increased loads due to the tolerances of the elevation in the crane hooks: Centre of gravity shift factor = 1.03 Tilt factor = 1.03 Ungraded

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2.

Tandem Lifting

if there are 2 slings to each hook, the load to each lift point shall be multiplied by a yaw factor, to account for tolerances in lift radii of the 2 hooks: Yaw factor = 1.05

3. For multi-hook lifts carried out by shear leg cranes (non-rotating crane), where the hook elevations are closely synchronized, the factors in Section 1 can be reduced by 50%. For shear leg type cranes on one vessel the yaw factor specified in Section 1 can be reduced to 1.0.

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Tandem Lifting

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10 Video

Chapter 10 Video

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11 Case Study

Chapter11 Case Study

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11 Assignment Day 2

Chapter11 Assignment Day 2

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End Of Day 2

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Day 3 – Lifting Plan 1.

RISK ASSESSMENT

2.

LIFTING PLAN CLASSIFICATION

3.

LIFTING PLAN CONTENTS

4.

METHOD STATEMENTS

5.

LIFTING DATA TABLE

6.

VIDEO ILLUSTRATION

7.

PRACTICAL TRAINING & ASSIGNMENT DAY-3

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1 Risk Assessment

Chapter 1 Risk Assessment

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Risk Assessment

Five Steps to Risk Assessment 1. Identify the hazards 2. Estimate the risk 3. Evaluate the risk 4. Record your findings 5. Review your assessment

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Risk Assessment

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2 Lifting Plan Classification

Chapter 2 Lifting Plan Classification

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Lifting Plan Classification

 Routine: A generic Risk Assessment and Lift Plan may be used for Routine Lifts; however, classifying a lifting operation as ‘Routine’ does not automatically make it a ‘Safe’ lifting operation – most incidents associated with lifting occur during ‘Routine’ operations. The Risk assessments and Lift Plans shall always be reviewed during the Toolbox Talk for continued applicability.  The control requirements and competencies for Routine Lifts can be summarized as follows: Ungraded

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Lifting Plan Classification

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Lifting Plan Classification

 Non-Routine Non-Routine lifting operations can be further sub-divided to reflect increasing risk: A. Simple lifting operations. B. Complicated lifting operations requiring a specific Lift Plan. C. Complex lifting operations requiring a specific Lift Plan with engineering input.  The control requirements and competencies for Non-Routine Lifts can be summarized as follows: Ungraded

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Lifting Plan Classification

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Lifting Plan Classification

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Lifting Plan Classification

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3 Lifting Plan Contents

Chapter 3 Lifting Plan contents

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Lifting Plan Content Criteria Section A (1) General Details

Standard

1. 2. 3. 4. 5.

Customer Name of site contact Phone number of contact Site location The description of lift

As stated in scenario As stated in scenario As stated in scenario Full description as scenario As stated in scenario

6. 7.

Section B (2) Loads The net weight of the load * The gross weight of the load *

8. 9.

Dimensions of the load * Position of the C of G *

As stated in scenario As calculated (uniform or central load)

10. 11.

Height of lift * Maximum radius *

From ground level to load bottom of load at any given point during the lift

12. 13.

Make & model * The required capacity *

As identified Must be the pre-determined ideal size and type

14. 15. 16. 17.

Main boom length required Fly jib length & angle Outrigger spread * Outrigger load (worst scenario) *

As As As As

As stated in scenario Calculated as weight of load (hook block & accessories with a minimum FOS identified)

Section C (3) Crane

18. 19. 20.

Maximum ground bearing pressure * All up weight of crane * Additional counterweights (if) Section D (4) Ground Conditions 21. Access & egress points for the crane * 22. Access & egress points for other transport 23. The required lifting positions * Section E (5) Lifting Accessories 24. The type and length required * 25. Correct WLL identified * 26. The number of lifting accessories required * Section F (6a) Proximity Hazards (as applicable)* 27. Overhead power lines * 28. Other types of overhead obstacles * 29. Underground services * 30. Excavations * 31. Unstable / soft ground * 32. Hazardous chemical / material * Ungraded 33. Confined working area *

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per per per per

crane specifications crane specifications crane specifications Crane Manufacturer, or as per CIRIA guidance for selected crane

As per specifications on scenario As per manufacturer specifications As per manufacturer specifications As stated in scenario As stated in scenario As stated in scenario Suitable type(s) identified Accurate Number identified Identified as Yes or No Identified as Yes or No Identified as Yes or No Identified as Yes or No Identified as Yes or No Identified as Yes or No Identified as Yes or No

Yes

No

35 34. 35. 36. 37.

Lifting Plan Content Identified as Yes or No Identified as Yes or No Identified as Yes or No Identified as Yes or No

42. 43. 44.

Restricted access – width * Restricted access – height * Other vehicles Other hazardous * Section F (6b) Load Hazards Slinging difficulties * Top heavy loads * “High Centre of Gravity” Sharp edged loads * Other hazards * Section G (7) Assessment of Risk Hazards (not included in 27 – 36) * Risks against hazards in item 42 * Action to be taken to avoid / reduce risk as in item 42 *

45. 46.

Risks against the hazards in item 27 – 36 * Action to be taken to avoid / reduce risk as in item 27 – 36 *

Identified as Yes or No Identified as Yes or No

47.

Section H (8) The equipment the crane must equipped with

Identified as Yes or No (must state if information contained in method statement)

48.

Customer provisions

Identified as Yes or No (must state if information contained in method statement)

49.

Section J (10) Personnel The number of additional personal required*

Must be minimum of 2, note: lifting at height or depth required minimum 3

38. 39. 40. 41.

Identified as Identified as Identified as Identified as

Yes Yes Yes Yes

or or or or

No No No No

Identified as Yes or No Identified as Yes or No Identified as Yes or No

Section I (9)

50. 51.

The type of personnel required * Any P.P.E. that personnel must be equipped* Section K (11) Weather / Environment & ground conditions

Identified as Yes or No Identified as Yes or No

52.

Conditions when lifting operation must be shut down *

As per crane manufacturer recommendations

53.

Identified as Yes or No

54.

Instruction to check wind speed at point of lift* Section L (12) Ground Conditions Ground conditions, and started all precautions to be taken *

55.

Section M (13) Sequence of operations The sequence of operations *

Logical order does not cause incident or greater & without confusion

56.

Include Contingency Plan *

Alternative lift method should factors change

57.

Section O (15) Drawings Did the drawing (Plan and Elevation) show the position of the crane *

Clear & identifiable

58.

Did the drawings correctly show the positioning of crane, load (before & after lift) & ancillaries

Clear & identifiable

59.

Clearly marked to scale *

Scale clearly identified matched to drawing and suitable to show details

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Identified as Yes or No

35

Lifting Plan Content Section P (16) Additional

60.

Were the contents of method statement understandable to others who may be involved in the lift *

Ungraded

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Clear, decipherable and coherent

4 Method Statement

Chapter 4 Method Statement

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45

Method Statement

Method Statement (BS 7121-3)  Document produced for or by the appointed person to describe how the lifting operation should be carried out, including any contingency plan if the operation becomes interrupted (e.g. because of weather change, break down, etc.)  A method statement should be prepared, by the appointed person, including a step-by-step description of the safe system of work for the entire lifting operation. The method statement should include at least the following:  a) the schedule of responsibilities (e.g. type of hire, road closures, base preparation, isolation of live services);  b) full details of the crane(s);  c) details of ancillary equipment;  d) details of the lifting accessories; Ungraded

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Method Statement

 e) the name of the appointed person;  f) the name of the crane supervisor  g) a complete plan including the sequence of the operation [from site preparation, arrival of the equipment on site, any necessary erection, positioning of the crane(s), lifting and placing of the load(s), and dismantling the crane(s), to moving off site]. NOTE 1 This list is not exhaustive and in some circumstances further in formation may be required.  During preparation of the method statement the appointed person should consult with any persons with specialized knowledge and experience, as appropriate, to ensure that all hazards that may be caused by, or to, the crane(s), are taken into consideration. Ungraded

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5 Lifting Data Tables

Chapter 5 Lifting Data Tables

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55

Lifting Data Tables

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55

Lifting Data Tables

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55

Lifting Data Tables

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55

Lifting Data Tables

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Lifting Data Tables

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6 Exercise and Day 3 Assignment

Chapter 7 Exercise and Day 3 Assignment

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End Of Day 2

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Day 4 – Examination 1.

WRITTEN EXAM

2.

WRITTEN EXAM (Lifting Plan)

Ungraded

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THE END

DNVGL THANKS YOU FOR YOUR ATTENTION.

Sacha Sarkissians [email protected] +971552580276

www.dnvgl.com

SAFER, SMARTER, GREENER Ungraded

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