crane safety and_awareness_presentation_ttp

Internal Use Only

Crane Safety and

Awareness

Internal Use Only

WPS Lifting Equipment Pull Testing

Policies and Procedures

• For safety reasons our customers are requiring stricter control

of lifting equipment certifications. As a company Halliburton

stresses safety as a daily practice.

• There are many types of equipment that will fall under the

category of “Lifting Equipment” in our operations. Listed below

are examples:

• Rig Up Equipment

• Lifting Slings

• Tool Lifting Caps

• Anything that is used as lifting equipment, used in lifting, or

that is lifted must be certified

Internal Use Only

Definition of Terms

• Maximum Working Tension: the maximum recommended

tension load applied on the wireline cable. The vendor’s

published information points us to 50% of the breaking

strength of a new line as the best general guideline for safe

pull on a cable.

• Working Load: the maximum allowable tension load that can

be placed on a piece of equipment.

• Hook Load: the load seen on the upstream side of a pulley

assembly. In our case it refers to the load above the top

sheave; twice that of the cable pull, as it crosses the sheave

wheel.

Internal Use Only

Definition of Terms

• Proof Load: the amount of tension that is to be applied to the

Lifting Equipment, in test to re-certify it for another year of

service. The Proof Load is higher than the working load to

allow for the dynamic nature (rapidly changing or shock) of the

loads seen in actual operations versus the static nature of the

Proof Load testing.

• Safety Factor: the Proof Load / Working Load. For overhead

lifting equipment, this is a 4:1 factor.

Internal Use Only

Definition of Terms

• Visual Inspection: lifting equipment should be visually

inspected any time it is used. It is recommended that this also

be performed on a monthly basis for seldom used equipment

and is mandatory during annual recertification.

Visual inspection should include the inspection of the

labeling to ensure it is still within certification and the

certification and ratings are still legible on the tag.

Internal Use Only

Load Testing

• It is the responsibility of the field operations location to re-

certify lifting equipment on an annual basis.

• Re-certification must include a Proof Test, mechanical

inspection of assemblies for wear or corrosion, and test

documentation (certificate & tagging). Lifting equipment

assemblies shall be tested up to but not exceeding their Proof

Load.

• It is required that a non-destructive material testing (dye

penetrate or magnetic particle / MPI) be completed on all cast

components of the assemblies to check for cracks or

inclusions.

Internal Use Only

Load Test Color Coding

• Color coding is mandatory for any equipment that has been

annually certified.

• Halliburton’s color coding system will not override a customer

color code requirement. If any customer requires a color code

for annual certification identification their color code will take

precedence over the Halliburton color code.

• The main purpose of color coding is to make it easy to identify

whether a lifting device or lifting point is within requirements.

The colors selected should be easy to see day or night, and

should be visible for an operator of a crane or fork lift.

Internal Use Only

Load Test Color CodingWPS Color Sequence for Annual Certification of Lifting Equipment

Notes:

1. The valid color code shall only be applied after satisfactory results of an inspection.

2. Other ways of color coding other than painting such as plastic, tags, etc. may be

required for polyester slings, items that get heavy use, etc.

3. Anything with an inspection interval different than one year should be identified

accordingly.

4. Customer Color Code requirements will take precedence over the Halliburton color

code.

5. Red Color Code will be used for equipment that is not fit for service.

Light Blue Fluorescent

Orange

Or

Bright Orange

Fluorescent

Green

Or

Bright Green

Fluorescent

Yellow

Or

Bright Yellow

1st Half Even Years

i.e. Jan – June 00,

02, 04, 06, 08

2nd

Half Even Years

i.e. July – Dec 00,

02, 04, 06, 08

1st Half Odd Years

i.e. Jan – June 01,

03, 05, 07, 09

2nd

Half Odd Years

i.e. July – Dec 01,

03, 05, 07, 09

Red is for

Equipment

that is Not Fit

for Service

Internal Use Only

What Color would I use to identify a piece of Lifting

Hardware that was Tested on December 3, 2010?

1 2 3 4

0 00

11. Fluorescent Yellow

2. Light Blue

3. Fluorescent Orange

4. Fluorescent Green

Internal Use Only

Hooks

Hooks MUST have a Safety Latch or Clip. This Prevents the Hook from Twisting out

of the Device it is Attached to.

If a Hook does not have a Safety Clip, or the Clip is Broken, DO NOT USE IT. Replace the Hook

or Have the Safety Clip Repaired

Internal Use Only

Visual Inspection of hooks

Internal Use Only

Visual Inspection of Hooks

Internal Use Only

Inspection of Shackles

Do not use Shackles that don’t have Bolt \ Nut \ Safety Pin!

Only use Approved Shackles

Internal Use Only

Tool Lifting Handcuffs

“This is the only Approved tool lifting chain device”

OEB 2002/058

Internal Use Only

Wire Rope Clips

“Never Saddle a Dead Horse”

Saddle on Live or

Load side of LineU-Bolt on

Dead or

Unloaded side

of the line

Internal Use Only

Rig Up Equipment

Do not use Wire Rope Slings to tie off Sheave Wheels!

Only use Certified Load Tested Chains

http://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST

-GL-HAL-WPS-421.pdf

Internal Use Only

Hand Tools

Break Over Style Chain Binders are not Recommended

Internal Use Only

Load Test Rating Tags

Make sure all chains, slings, clevises, sheave hangers, and

anything involved in wireline rig up has a load test rating

certification tag that is legible.

DO NOT USE ANY EQUIPMENT THAT IS NOT LEGIBLY TAGGED!

Internal Use Only

Sheaves

Sheave Wheels

Come in various diameters to Match different cables

Inspected, Load Tested & Certified Annually

Internal Use Only

Sheaves

OEB - 2009/021

Internal Use Only

Sheave Wheel Hand Guard

OEB-2009/082

Internal Use Only

Sheave Wheels

Groove too narrow

Pinches cable

Correct groove

Cable well supported

Groove too wide

Cable squashed

Internal Use Only

Tool Lifting Caps

• All lifting caps must be certified annually with a proof test of

10,000lbs and a dye penetrant inspection on each cap. To

track the testing all caps must be serialized in each location.

Internal Use Only

Tool Lifting Caps

Internal Use Only

Pressure Gear Lifting Caps• The recommended lifting devices for pressure control

equipment include lifting clamps, spreader bars, lifting caps

and slings of the proper size for the rig up hardware being

hoisted. Clamps and Spreader Bars are used to rig up lubricators on the

well site.

Lifting Caps are used to move and rig up BOP and heavy cross

over adapters.

All of these items must be certified and have original manufacturing

and testing documentation on file. This equipment must

successfully undergo a proof load test of 2 times the working load

rating prior to first entering service and must be subjected to visual

inspections before each use and annual certification to remain in

service. All lifting equipment must be clearly marked with a

permanent serialized part number and identified with the Working

Load Limit rating.

Internal Use Only

Pressure Gear Lifting Caps

Internal Use Only

Boxes, Pallets, Skid Pad Eye

Inspection Criteria

• Inspect pad eye on offshore boxes, containers, pallets, skids

for the following: Check the tag for certification and load rating

Wear

Nicks, Cracks, Gouges

Modifications

Internal Use Only

Boxes, Pallets, Skid Pad Eye

Inspection Criteria

• All lifting containers must have the following: Be permanently marked with the maximum load capacity.

Have clearly identified lifting points capable of handling the total

capacity of the load.

Have machined pad eye or lifting points (not flame cut).

Have undamaged lifting points or pad eyes.

All pad eyes should be visually inspected before every use. In

addition, all pad eyes require and annual certification. Annual

certification includes a visual inspection, a load certification and an

MPI or dye penetrant.

Each lifting point must carry the current corresponding color code.

Internal Use Only

Boxes, Pallets, Skid Pad Eye

Inspection Criteria

• Lifting Container lift test procedure: A visual inspection will be carried out on the pad eyes and the

container being tested.

Container shall be loaded to a total weight of the maximum load

capacity rating of the container and lifted using all the pad eyes.

Test load should be evenly distributed inside the container.

Container shall be lifted by a standard lifting set and should be

held, clear of the ground, throughout the test.

The force should be applied using calibrated weights and lifting the

container by means of a suitable test rig or crane.

The date of inspection should be indicated on the container

(preferably on a plate fitted specifically for this purpose).

Internal Use Only

Boxes, Pallets, Skid Pad Eye

Inspection Criteria

Internal Use Only

Basic Sling Configuration

Vertical ChokerVertical BasketVertical Eye to Eye

1 Ton 2 Ton 75 to 80% of Vertical Hitch

Nylon

Internal Use Only

Synthetic Sling Inspection Criteria

• Inspect synthetic slings for the following: Check the tag for certification and load rating

Acid or Caustic Burns

Melting or Charring

Holes, Cuts, Punctures, Crushed Fabric

Tears, Snags

Broken Stitches

Worn Stitches

Excessive Abrasion or Wear on webbing or fittings

Knots

Discoloration

Anything that causes doubt to the continued use of the sling

Internal Use Only

Synthetic Sling Inspection Criteria

• Additional requirements for synthetic web slings include: Each sling must be clearly marked to show the rated capacities for

each type of hitch, web material and manufacturer.

Slings must contain web that is of uniform thickness and width, and

the edges must not be split from the webbing width and must not

be unraveling.

Fittings must be free of all sharp edges that could damage the

webbing and must me of a minimum breaking strength equal to that

of the sling.

Stitching shall be the only method used to attach end fittings to

webbing and to form eyes.

Nylon and polyester slings must not be used at temperatures above

200 deg F.

Internal Use Only

Internal Use Only

Internal Use Only

Steel Chain Inspection Criteria

Bent Links

Cracks in Welded Areas, Shoulders, or any other section of the link.

Excess wear in the Bearing Surface of the Link.

Transverse Nicks and Gouges.

Corrosion Pits

Stretching Caused by Overloading.

Increase in reach of the Sling as compared to its Original Length

Internal Use Only

Steel Chain Inspection Criteria

“A Chain is only as Strong as its Weakest Link”

Internal Use Only

Wire Rope Slings

• Inspect wire rope slings for the following: Check the tag for certification and load rating

Kinking, crushing or other damage that results in detrimental

distortion of the rope structure

Bird caging

Unstranding

Unlaying or opening up of a tucked splice

Strand Displacement

Core Protrusion form an opening between strands

Any marked reduction in diameter wither along the entire main

length or in one section

Corrosion

Wear or scraping of one-third the original diameter of outside

individual wires

Internal Use Only

Wire Rope Slings

Internal Use Only

Wire Rope Slings

Internal Use Only

Wire Rope Removal

Internal Use Only

Wire Rope Removal

Internal Use Only

Wire Rope Removal

Internal Use Only

Calculating Sling Loads

4 ft

5.656 ft

Load Angle Factor = Sling Leg Length Height from Pick Point

Load x Load Angle Factor Number of Sling Legs = Tension in Each Sling Leg

Internal Use Only

10,000 lbs

8 ft

4 ft

10,000 lbs

8 ft8 ft

5 ft

4 ft

6 ft

10,000 lbs

8 ft8 ft

5 ft

4 ft

8 ft

Length/Height = Load Angle FactorL/H = Load Angle Factor

L/H = 8/4 = 2 (10,000 x 2)/2

20,000/210,000 lbs Tension

L/H = 8/5 = 1.6(10,000 x 1.6)/2

16,000/28000 lbs Tension

L/H = 8/6 = 1.3(10,000 x 1.3)/2

13,000/26500 lbs Tension

(Load x Load Angle Factor)/Number of Sling Legs = Tension in each Sling Leg

Internal Use Only

Effect of Sling Angle

11025 11195 1173312731

14392

17152

22050

90 80 70 60 50 40 30

Degree of Angle

Ten

sio

n i

n P

ou

nd

s

As the sling angle decreases towards the horizontal

the stress applied to the sling increases.

“The minimum angle allowed is 30 ”

Halliburton Best Practices

Minimum Sling Angle

Internal Use Only

Internal Use Only

Man \ Aerial Lift

Internal Use Only

• Requires Orientation Course Including Hands on

Exercise and Skills Test

• Employee’s are Not to Operate Man \ Aerial Lifts Prior

to Qualification and Authorization

Man \ Aerial Lift

Internal Use Only

• Every 3.6 Dropped Object Incidents = 1 Injury

• Every 26 Dropped Object Incidents = 1 Fatality

Dropped Object Statistics

Internal Use Only

What is a Crane?

• A crane is a mechanical lifting device equipped with a

winch, wire rope and sheaves that can be used both to

lift and lower materials \ objects and to move them

horizontally.

• It uses one or more simple machines to create a

mechanical advantage and thus move loads beyond

the normal capability of a human.

Internal Use Only

Telescopic Boom Sections

Boom Trucks

Base (Heel) Section

Boom rest

Boom lift Cylinder

Optional Front

Stabilizer

Outrigger

Winch

Load Line

Load Handling Device

Operator Controls

Various Parts of the Hydraulic Mobile Crane or Boom Truck Crane

Turret

Center of Rotation

Internal Use Only

Crane Configuration

Boom Length illustrated with the green line is

measured from the Boom Hinge Pin to the Center of

the Boom Tip Sheave

Boom Angle is represented with the blue lines and is the Angle of the Main Boom as compared to Horizontal

Load Radius shown here with red lines is the Distance Measured Horizontally from the Center of Rotation to the Center of Gravity of the Load

Boom Angle is read from the Boom Angle Indicator on the side of the boom

Internal Use Only

Center of Gravity

The point on the load where the load is distributed evenly.

Internal Use Only

Center of Gravity & Center of Balance

The point on the load where the load is distributed evenly in all directions

The balancing point on an object

Internal Use Only

Crane Leverage & Tipping Fulcrum

Internal Use Only

Area of Operation(360 Degrees Chart)

Internal Use Only

Lift Planning

Questions that must be answered prior to

making a lift:

What is the surface that the crane will be setup on?

Will you be able to level the crane properly?

Are there environmental concerns effecting this lift?

Internal Use Only

Lift Planning Continued

What is the longest radius that will be reached?

What is the heaviest load that will be lifted?

What is the Crane manufacturer’s rated load capacity?

What percent of rated capacity will be utilized?

Will this become a Critical Lift?

Internal Use Only

Critical Lift Criteria

Weight of the Load exceeds 80% of the cranes capacity

Complexity of the Lift “line of sight issues, multiple cranes, etc.”

Consequences of failure “loss of life, monetary value, etc.”

Internal Use Only

Load Handling Devices

Load Block or Hook Block Headache Ball,

Overhaul Ball or

Downhaul Weight

Internal Use Only

Weight

Rated Capacity

Manufacturer

Required Information for Rigging

Hardware

Internal Use Only

Rigging Safety Guidelines

Know the Weight of the Load

Know the Center of Gravity of the Load

Make Load Attachment Above Center of Gravity

Know Rated Capacities of Slings and Rigging Gear

Inspect All Rigging Gear Prior to Use

Protect Slings from Sharp Edges

Allow for Increased Tension Caused by Sling Angle

Attach Tag Line Prior to Lift

Internal Use Only

Rigging Safety Guidelines

Keep Personnel Clear of Lift Area

Lift Load a Few Inches and Re-Check Rigging

Know Limitations of Rigging Gear

Start and Stop Slowly

Watch for Obstructions and Power Lines

Use Proper Hand Signals

Maintain Load Control

Do Not Forget the Law of Gravity

Internal Use Only

Operational Aides

Anti-Two-Block Load Moment Indicator Boom Angle Indicator

Level Indicator

Internal Use Only

Anti-Two Block

Anti-Two-Block Alarm

Sensors

Weight

The Anti-two blockswitch prevents a twoblock condition by limiting the followingcrane functions:

1. Hoist up

2. Boom extension

3. Boom down “depending on crane configuration or manufacturer specifications”

A two block condition is when the load handling device contacts the boom tip.

Internal Use Only

Load Moment Indicator

Internal Use Only

Boom Angle Indicator

Internal Use Only

Level Indicator

Internal Use Only

Changes in Load Radius

Increase in Load Radius Decrease in Load Radius

Low side Longer Radius High side Shorter Radius

Internal Use Only

Changes in Load Radius

(Load Swing)

Internal Use Only

Changes in Load Radius

Possible Capacity Loss When Out of Level

Boom Length and Radius Degree out of Level

1 2 3

Short Boom, Maximum Radius 10% 20% 30%

Short Boom, Minimum Radius 8% 15% 20%

Long Boom, Maximum Radius 30% 41% 50%

Long Boom, Minimum Radius 5% 10% 15%

Internal Use Only

Outriggers and Ground Conditions

Crane was tipped with an Unloaded Boom“notice that outriggers were down, but not extended”

Internal Use Only

Outriggers are down but not extended

Outriggers and Ground Conditions

Internal Use Only

Outriggers and Ground Conditions

Internal Use Only

Outriggers and Ground Conditions

Internal Use Only

Safe Operating Practice

Internal Use Only

Side Loading

Internal Use Only

Internal Use Only

Internal Use Only

Internal Use Only

Internal Use Only

Hand Signals

A Stop Signal Shall be Obeyed by the Operator Regardless of who Gives it.

“Whether Verbal or Hand Signal”

Internal Use Only

Hand Signals

Signals Shall be Discernable at ALL Times.

“No Response Shall be Mad Unless Signals” are Clearly Understood

Internal Use Only

Hand Signals

All Directions Given to the Crane Operator by the Signal Person Shall be Given from the Crane

Operators Direction Perspective

Internal Use Only

Hand Signals

Internal Use Only

Hand Signals

Internal Use Only

Environmental Effects

Internal Use Only

Internal Use Only

Internal Use Only

Internal Use Only

Working Near Power Lines

The preferred condition under which the operation can be performed is if the hazard of

injury or death due to electrocution has been removed.

The following steps shall be taken to assure de - energization of the power lines:

The power company or owner of the power lines shall de-energize the lines.

The lines shall be visibly grounded to avoid electrical feedback and appropriately

marked at jobsite location.

A qualified representative of the owner of the lines or a designated representative

of the electrical utility shall be on the site to verify that all steps have been

completed and that the lines are not energized.

Durable signs shall be installed at the operator’s station and on the outside of the

crane warning that electrocution or serious bodily injury may occur unless minimum

clearances, as specified in Table 2 are maintained between the crane or the load

being handled and energized power lines.

Internal Use Only

Lighting

Crane operations should cease in advance of storm nearing the area where

crane operations are being conducted.

The load should be landed, boom retracted and placed back into the boom rest.

As a best practice you may resume work 30 minutes after the electrical storm has passed.

Internal Use Only

Wind

Internal Use Only

Wet and Boggy

Internal Use Only

Cold Weather

Crane Operations should be shut-down at - 40°F

Internal Use Only

Manufacturer

Internal Use Only

Crane Inspection Form

Internal Use Only