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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
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
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