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LIFTING EQUIPMENT MANAGEMENT SYSTEM

FOR PETRONAS CARIGALI SDN. BHD

PENINSULAR MALAYSIA OPERATION

MASTER DOCUMENT

Lifting Equipment Management System PCSB LEMS 05 001 LEMS Rev. 0 Jan ‘05’

PETRONAS CARIGALI SDN BHD – LEMS – Rev. 0 of 189

Table of Contents: Executive Summary Section 1 LEMS-01 Introduction 1.1 Introduction 1.2 Purpose 1.3 Objectives 1.4 User 1.5 Responsibilities 1.6 References Section 2 LEMS-02 LEMS Document Control 2.1 Record of Revision 2.2 List of Distribution Section 3 LEMS-03 Definitions & Abbreviations Section 4 LEMS-04 System Documentation 4.1 Objectives 4.2 Existing Procedures 4.3 Measurement 4.4 Attachments Section 5 LEMS-05 Management of Change Procedures 5.1 Introduction 5.2 Definitions & Scope 5.3 Change Type Requirements 5.4 Change Originator Requirements 5.5 Documentation & Process 5.6 Attachments Section 6 LEMS-06 Site Procedures 6.1 Introduction 6.2 Definitions 6.3 SSLP Development Overview 6.3 Development Section 7 LEMS-07 Lifting Equipment Standards 7.1 All Equipment Covered by LEMS



Section 8 LEMS-08 Hoisting & Rigging Equipment 8.1 Objectives 8.2 Identification & Colour Coding 8.3 Hoisting Equipment Maintenance 8.4 Hoist Operation 8.5 Rigging/Slinging Practices 8.6 Safe Use of Wire Slings 8.7 Safe Use of Flat Woven Slings 8.8 Safe Use of Round Slings 8.9 Hooks, Shackles & other Hardware 8.10 Lifting Beams & Frames 8.11 Safe use of Wire Ropes 8.12 Slinging Angle Information 8.13 Slinging of Tubulars 8.14 Protection of Slings & Loads 8.15 Selection & Labelling of Slings 8.16 Safe Use of Equipment 8.17 Winches 8.18 Fixed Lifting Equipment 8.19 Fabricated Padeyes & Lifting Points Section 9 LEMS-09 Lifeboat Davits & Winches 9.1 Operation 9.2 Equipment Maintenance Section 10 LEMS-10 Lifting Operations & Maintenance 10.1 Introduction 10.2 Standards 10.3 Offshore Pedestal Cranes 10.4 Mobile Cranes 10.5 Overhead Cranes 10.6 Forklifts 10.7 Personnel Lifting Devices 10.8 Securing of Loads 10.9 Hydraulic Hoses 10.10 Hydraulic Parts & Equipment Section 11 LEMS-11 Training & Certification 11.1 Assessor/Trainer Qualifications 11.2 Crane Operator 11.3 Signal Man 11.4 Crane Inspectors/Load Testers 11.5 Rigger/Load Handler Section 12 LEMS-12 Third Party Services 12.1 Vendor Monitoring Section 13 LEMS-13 Risk Assessments 13.1 Job Hazard Analysis 13.2 Deck Management Section 14 LEMS-14 Incident Investigation 14.1 Lifting/Dropped Object Incidents Section 15 LEMS-15 Emergency Procedure



Petronas Carigali Sdn. Bhd.

Lifting Equipment Management System

(LEMS)

Executive Summary

In the spirit of PCSB’s Zero Tolerance Safety Culture, the Lifting Equipment Management System (LEMS) has been developed to as far as is practicable “eliminate” all crane and lifting related incidents at all PCSB Locations, which may pose a threat to people and assets in the direct or indirect vicinity on or offshore. This includes the environment directly around us. To ensure that through selection and ongoing training, the LEMS will be able to establish and sustain a competent workforce with a varying degree of lifting expertise within PCSB and contracted personnel. In the knowledge that all injuries can be prevented, and there are no task(s) more important than our personnel, PCSB Managements’ ultimate aim is the well being of all of our employees.



Section 1 LEMS-01 1.1 Introduction

This document contains an overview of safe operating procedures, instructions, and guidelines for conducting routine and non-routine lifting operations with the goal of the elimination of injury to personnel, damage to Petronas Carigali Sdn. Bhd. Assets, threats to operational integrity or damage to the environment at all PCSB offshore & onshore locations.

1.2 Purpose

The PCSB LEMS (Lifting Equipment Management System) has been developed to meet the following but not limited to criteria:

• To “eliminate” all crane and lifting related incidents during all

operations which may pose a threat to people in the direct or indirect vicinity on or off the platform, this includes the environment directly around us.

• Through selection, training and ongoing training, we will be able to establish and sustain a competent workforce with a degree of lifting expertise within PCSB and contracted personnel.

• To initialise and measure continuous improvement, a maintenance and inspection program, such that the integrity of all lifting equipment on PCSB Platforms will be further enhanced.

• To ensure the LEMS is adhered to, with more emphasis on abnormal loads and lifts, is structured and maintained to always meet the requirements of safe operations.

1.3 Objective

The objective of the LEMS is to provide an overview of safe operating procedures, instructions and guidelines for conducting routine and non-routine lifting operations at all PCSB offshore & onshore locations without injury to personnel, damage to PCSB assets, threats to operational integrity or damage to the environment.

Strategies for achieving these objectives are to: • Clearly assign roles and responsibilities for the management of lifting

operations, • Fully implement competency assurance policies and programs and

ensure that all personnel involved in lifting operations are fully trained and competent to carry out their duties,

• Ensure that all lifting equipment is inspected and tested on a regular basis in compliance with regulatory requirements and applicable standards,

• Ensure that all lifting activities go through required lift planning processes and are properly evaluated and endorsed prior to execution,

• Implement a selection process to identify competent service suppliers, that meet the standards (API) through the pre-qualification of equipment and operators,

• Periodically assess and continually improve the LEMS.



1.4 Users

The intended users of this manual include:

PCSB Personnel Asset Managers, Heads of Operations, PTS Head, Asset Engineers, Maintenance Support Group Superintendent, PCSB Platform Superintendents. Service Providers Crane Operators, Crane Technicians, Banksman/Signal Man, Riggers, Drilling Personnel, All other Third Party personnel deemed necessary by the Platform Superintendent of the PCSB offshore or onshore Facility.

1.5 Responsibility 1.5.1 Purpose

The objective of the LEMS is to provide an overview of safe operating procedures, instructions and guidelines for conducting routine and non-routine lifting operations at all PCSB locations without injury to personnel, damage to PCSB assets, threats to operational integrity or damage to the environment at all PCSB locations. Operations management are responsible for ensuring that these goals are reached. This LEMS has been developed to contain the system documentation, and guidelines for the development routine, standard and Site Specific Procedures. The Manual will be referred to as the LEMS.

1.5.2 Responsibility of Line Management

Line management personnel are responsible for: • Maintaining familiarity with the contents of the LEMS Manual as it

applies to operations under their authority, • Ensuring that the LEMS Manual is readily available for use by

appropriate personnel, • The implementation and continuous use of the LEMS Manual, • The ongoing assessment of the contents of the LEMS Manual, • The fostering of efforts for the continuous improvement of the

procedures, instructions and guidelines found within the LEMS Manual.



1.5.3 Responsibility of the Asset Engineer

The Asset Engineer is responsible for: • Maintaining familiarity with the contents of the LEMS Manual, • Ensuring that the LEMS Manual is properly distributed, • Fostering efforts by line management in the implementation and

continuous use of the Manual, • The ongoing assessment of the contents of the LEMS Manual, • The fostering of efforts for the continuous improvement of the

procedures, instructions and guidelines found within the LEMS Manual, Serving as the LEMS Manager.

1.5.4 Responsibility of the Operations Supervisor

The Operations Supervisor is responsible for ensuring that the personnel for whom they are responsible for are familiar with the manual, and that the manual remains current at all times. In achieving these goals, the Operations Supervisor shall encourage and motivate all Users in the use of this manual

1.5.5 Responsibility of the MSG Superintendent

The MSG Superintendent, for the Heavy Equipment and Maintenance Support Group is responsible for: • Maintaining familiarity with the contents of the LEMS Manual, • Ensuring that the LEMS Manual is properly distributed to line

management, • Fostering efforts by appropriate subordinate personnel in the

implementation and continuous use of the Manual, • The ongoing assessment of the contents of the LEMS Manual, • The fostering of efforts for the continuous improvement of the


1.5.3 Responsibility of Service Providers

All Service Providers are responsible for: • Maintaining fluency with the contents of the LEMS Manual as it

applies to operations under their authority, • The implementation and continuous use of the LEMS Manual, • The ongoing assessment of the contents of the LEMS Manual, • The fostering of efforts for the continuous improvement of the


1.5.7 Responsibility of the User

All employees and contractors onshore or offshore who, through their work, identify or effect a change to any system, process, or procedure described in this manual shall: • Report the change effected or discrepancy noted to their Supervisor; • Include a revision of this manual or at minimum the affected parts of it,

as a required element of the documentation of the work being carried out.



1.6 References 1.6.1 CIMG – Carigali Inspection & Maintenance Guidelines, 1.6.2 CCMG – Carigali Maintenance Management Guide, 1.6.3 PCSB Management of Change Document – 1999, 1.6.4 HSEMS – HSE Management System – 2.2-010, 1.6.5 PTW – Permit to Work (Lift Permits), 1.6.6 Job Hazard Analysis, 1.6.7 API-2C Specification for Offshore Pedestal Mounted Cranes, 1.6.8 API-RP2D Recommended Guidelines for Operation & Maintenance of

Offshore Cranes, 1.6.9 API-9A Specification for Wire Rope, 1.6.10 API Recommended Practice 9B Application, Care and Use of Wire Rope, 1.6.11 API-RP8B Recommended Practice for Procedures for Inspections,

Maintenance, Repair and Remanufacture of Hoisting Equipment, 1.6.12 Bridon Ropes Publication, 1.6.13 ASME – B30.16 – Overhead Hoists, 1.6.14 ASME – B30.21 – Manually Lever Operated Hoists, 1.6.15 ASME – B30.9 – Slings, 1.6.16 ASME – B30.5 – Mobile Cranes, 1.6.17 ASME – B30.17 – Overhead Cranes, 1.6.18 ASME – B56.10 – Forklifts, 1.6.19 Billy Pugh Company Specifications.



Section 2 LEMS-02 Document Control 2.1 Record of Revision

CCHHAANNGGEE MMAANNAAGGEEMMEENNTT CCOONNTTRROOLL SSHHEEEETT

This Manual is a Controlled Document and will be subject to Management Procedures. Review of this Manual will be recorded in a PCSB Controlled Document System. Revision to this Manual will require the completion of the LEMS Revision Request Form. Endorsement and Approvals for Revisions and Updates will be required from the Asset Managers.

Copyholders of this Manual will be responsible for completing the Change Management History Sheet, which contains: • Revision No., • List of Page(s) to be replaced, • Copy No., • Date of Completion of Change, • Signature of Person completing the Change.

On completion of the insertion of the replacement Page(s) the person responsible for the Change implementation will verify that the replaced page(s) have been destroyed.

An Example of a Change Management History Sheet Revision No. Page(s) Changed Copy

No. Date of Completion

Signature of Person Completion the Change

Old Pages Destroyed

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes



2.1 Record of Revision Continued

EEXXAAMMPPLLEE OOFF AA RREEVVIISSIIOONN RREECCOORRDD AANNDD HHIISSTTOORRYY Current Revision Rev. No. Date

Description of Changes

Owner Signature: Title: Date:

Administrator Signature: Title: Date:

Approver Signature: Title: Date:

Revision History Rev. No. Date Description of Change Owner Administrator Approved



2.2 List of Distribution

Distribution List

The following is the list of all proposed holders of this document: Copy No.

Document Holder

0. Original – Master Document, PCSB/KOP

1. PCSB/PMO General Manager

2. PTS Manager

3. PTS 3 Section Head

4. PCSB Safety Department

5. Duyong Asset Manager

6. Duyong, Resak, OGT PTS

7. PM9 Asset Manager

8. Bekok Field PTS

9. Tiong/Kepong, Pulai/Tinggi, PTS

10. Dulang Asset Manger

11. Dulang PTS

12. Angsi Asset Manager

13. Angsi PTS

14. (MSG) Maintenance Support Group Superintendent

15. Duyong Platform Superintendent

16. Bekok Field Platform Superintendent

17. Tiong/Kepong, Pulai/Tinggi Platform Superintendent

18. Dulang Platform Superintendent

19. Angsi Platform Superintendent

20. KSB Base Superintendent

21. OGT Terminal Superintendent

22. Crane & Lifting Contractor



Section 3 LEMS-03 Definitions & Abbreviations Term Description

ABS American Bureau of Shipping AC Alternating Current ACoP Approved Code of Practise Anti-two-block device

A device which, when activated, disengages the hoisting operation to prevent the hook block assembly from coming into contact with the boom point sheaves assemblies. Also known as an “overhoist assembly” ATB.

ANSI American National Standards Institute API American Petroleum Institute Appropriate Is the replacement of any part of the system that does not alter

in any way its original design or capabilities. ASME American Society of Mechanical Engineers Auxiliary hoist A secondary hoist rope system, usually of lighter load capacity

than provided by the main rope system; also known as “whip line” or “fast line”.

Backstop Structure On the ‘A’ Frame that stops the boom from going over the back of the crane in a high wind or sudden release of the load.

Band Brake Circular brake, of either external expanding or internal expanding type, with a contacting surface of heat and wear resistant material.

Banksman See Signal Man Bight The bend of a line, rope, or cable. Block Sheaves or grooved pulleys in a frame supporting a hook; also

known as a “hook block”. Boom (crane) A member hinged to the rotating superstructure and used for

supporting the hoisting tackle. Boom angle The angle of the longitudinal axis of the base boom section

above or below horizontal. Boom chords Main structural members of a lattice type boom. Boom foot The base of the boom, where it is attached to the rotating

superstructure. Boom head Sheaves, pins, and other mechanisms at the top, or peak, of

the boom; also known as the “cathead”. Boom hoist A mechanical device used for supporting the boom and

controlling the boom angle; also known as the “derricking” or “luffing” system.

Boom hoist brake Brake to control the drum that the boom hoist line winds on. Boom hoist line Rope used to control boom movement in a vertical plane. Booming The movement of the boom through an angle from one radius

to another; also known as “luffing”. Boom lacing Structural truss members at angles to, and supporting, the

boom chords of a lattice type boom. Boom length The straight line distance from the centre of the boom foot pin

to the centreline of the boom point load hoist sheave pin. Boom sections A crane boom is usually in two sections, upper and lower, and it

may be lengthened by insertion of one or more intermediate sections.

Lifting Equipment Management System PCSB LEMS 05 001 LEMS Rev. 0 Jan ‘05’ Boom stop A device used to limit the angle of the boom at the highest

recommended position Booming in/out Retracting or extending, respectively, a telescopic boom. Booming up/down

Raising or lowering, respectively, the boom.

Bridle A frame equipped with sheaves and connected to the boom by stationary ropes usually called pendants; usually known as a “floating harness”.

Centre pin A large pin or vertical shaft acting as the centre of rotation for the revolving frame; also known as the “kingpin” or “kingpost”.

Centre of rotation The centre pin or rotational centre point on the crane from which the lifting radius is measured. It is the centre of the circle scribed by a full rotation of the crane.

Certificate of Examination

A certificate issued by the competent person (see Competent Person) giving the results of a thorough equipment examination. This will detail any defects found or include a statement that the equipment is fit for continued use. The Certificate must be retained for inspection when required.

Change A change is a modification to an approved system and or equipment.

CM Corrective Maintenance COG Centre of Gravity Colour Code A method of marking equipment, (normally with paint) to give a

readily visible indication of its certification status. This colour should be changed at each periodic examination.

Competent Person

In terms of lifting equipment inspection, one who has the requisite theoretical and practical knowledge and experience of the type of equipment under examination to certify, with confidence, that it is free from patent defect and suitable in all aspects for the duty for which the equipment is required.

Contractor A Company or persons who have a direct contract with the “Parent Company”

Counterweight Weight used to supplement the weight of the machine in providing stability for lifting loads. The weight is also known as “ballast” and usually attached to the rear of the machine.

Critical component

Any component of the crane assembly and/or restraining device whose failure would result in an uncontrolled descent of the load or an uncontrolled rotation.

Cross-over points

In multiple layer spooling of a rope on a drum, those points of rope contact where the rope crosses the preceding rope layer.

Designated Selected or assigned by the employer or the employer’s representative as being qualified to perform specific duties.

DOSH Department of Safety & Health Drum The cylindrical member around, which a rope is wound for lifting

and lowering the load or boom. Dynamic loading Loads introduced into the machine or its components due to

accelerating or decelerating forces. Factor of Safety The ratio of the load that would cause failure to an item of lifting

equipment to the load that is imposed upon its service, i.e. SWL. The Factor of Safety is to allow for detrimental criteria such as wear and tear and dynamic loading.

FDM Field Drilling Manager Fly Jib An extension fitted to the main boom over which a secondary

hoist system is fitted; also known as an “auxiliary jib”. Free Fall A boom or hook block descending by its own weight.



Gantry A structural frame, extending above the superstructure to which the boom support ropes is reeved; also known as “mast” or “A-Frame”.

Gross capacity Total crane lifting capacity as printed in the load chart. Includes load weight, rigging weight, hoisting line weight, etc.

Guy Rope A non-operating standing wire which maintains a constant distance between the points of an attachment to the components connected by the wire rope; also known as a “pendant wire”.

Hoist drum brake Brake to control the drum containing the load hoist line Hoist mechanism A hoist drum and rope reeving system used for lifting and

lowering loads. Hookblock see: Load block Hoist System The process of raising or lowering loads.

HOL Height of Lift Hook Rollers Rollers which prevent the lifting of the revolving superstructure

from the roller path. Hook rollers are the means to connect the superstructure to the foundation or pedestal.

In-Appropriate Is the replacement of any part of the system that does alter in some way its original design or capabilities.

In-service Inspection

A visual inspection, carried out by the responsible person, to check for obvious evidence of damage or wear which might affect the equipment’s for use.

ISO International Standardization Organisation Jib An extension attached to the boom point to provide added

boom length. The jib may be in line with the boom or offset to various angles in the vertical plane of the boom.

Jib backstop A device which will restrain the jib from turning over backward. JHA Job Hazard Analysis Kgs Kilograms KOP Komplex Operation Petronas KSB Kemaman Supply Base Lattice Boom Boom of open construction with angular or tubular lacing

between main corner members (chords) in the form of a truss. lbs Pounds Lifting Appliance Any machine which is able to raise, lower, or suspend a load

(e.g. crane, forklift, powered hoist), including its attachments for anchoring, fixing, or supporting it (e.g. beam trolleys, beam clamps, sheave blocks, winches, runway beams, and padeyes), but excluding machines incorporating a guided load (e.g. lifts) and continuous mechanical handling devices (e.g. conveyors).

Load block A metal frame suspended from the hoist line for mounting wire rope sheaves (pulleys) and having a hook at the lower end to attach the load. Also known as a hook block.

Lifting capacity The load that a piece of equipment can safely handle. Lifting equipment A generic term used to indicate, loosely, all lifting gear and

machines. Lifting gear An item used to connect a load to a lifting machine, but which is

not itself capable of providing any movement to lift or lower the load.

Limiting Device A device fitted to the boom and hoist motions designed to prevent over booming or over hoisting by sounding and/or isolating the motion.

Line pull The maximum pulling force exerted by a drum on the wire rope at full load.



Load chart A table published by the crane manufacturer showing the allowable (legal) gross lifting capacity for various lifting radii and boom lengths for each crane or crane configuration; also known as a “capacity chart”, “rating chart”, “lift chart”, and “maximum allowable capacity chart”.

Load hoist Line wire rope used to raise and lower the load being lifted. Also known as a lift line.

Load indicator A device that measures and displays the weight of the load. Load radius indicator

A device to show the crane operator the radius at which his boom is set and the safe working load at that radius; also known as “safe load indicator”.

Load Test See Proof Test Loose Lifting Gear

All equipment that can be removed from its present location and can be reinstated in another. These include, but are not limited, to the following examples: Shackles, Eye Bolts, Chain Blocks, Lever Hoists, Powered Chain Hoists, Manual Trolleys, Mono Rails Rope Pulling Machines (Tirfors), Portable Winches (Air and Hydraulic), Beam Clamps, Wire & Chain Slings, Fibre Slings, Round & Flat, Stinger Lines, Turnbuckles, Safety Harnesses & Inertia Reels, Snatch Blocks, Wire Rope Grips

Luffing Changing boom angle (see also booming up/down). Manufacturer’s Certificate

A certificate issued by the manufacturer stating that their product conforms to a particular standard and containing such information as is required by the referenced standard.

MAR Maintenance Action Request Master Clutch A device which disengages the prime mover from all motions of

the crane. Master Link A forged or welded steel link used to support all members (or

legs) of an alloy steel chain sling or wire rope sling. MT Metric Tonne MMS Mineral Management Safety MOC Management of Change Mousing A short length of cord or wire used to secure a hook which does

not have a safety catch. MPI Metal Particle Inspection MSG Maintenance Support Group NDT Non Destructive Testing Net lifting capacity

Crane capacity after weight of all attachments, e.g. hook block, spreader bars, hoist rope, jibs, etc, is subtracted from the gross capacity. On outriggers refers to outriggers deployed and (usually) tires off the ground. On rubber refers to truck or rough terrain cranes lifting without outriggers deployed.

Non-rotating wire rope

A rope whose inner and outer layers are laid in opposite directions to minimize the amount of twist occurring when the rope is used under variable tension.

OEM Original Equipment Manufacturer Operator’s Station

The designated location for the Operator when operating a particular machine or device.

Overhaul Ball The weight on a single part line used to pull the wire rope off the drum with gravitational assistance; also known as a “headache ball”.

PA Public Address



Parent Company The Company who owns or operates the offshore oil/gas platform.

Pawl A device for positively holding a member against motion in one or more directions; also known as a “dog”.

PCSB Petronas Carigali SDN. BHD. Pendant A rope of specified length with fixed end connections. Permanent: Is a modification to an approved system and or equipment for

an indefinite time. Personnel Basket Personnel work platform with sides. The platform, or basket, is

designed for personnel occupancy and can be hoisted into work position by a crane; also referred to as a “work basket”.

PIC Person In Charge Plant Identification Number

A unique number given to an item of lifting equipment for registration purpose and to facilitate traceability.

Power-controlled lowering

A system or device in the power train, other than the load hoist brake, which can control the lowering speed of the load hoist mechanism.

PPM Planned Preventative Maintenance Proof Test A Proof (or Load) Test is a process whereby a load (exerted by

gravity or other means) applied by the manufacturer or competent person for the purpose of a test. The applied load appears on the test certificate.

PSI Pounds per Square Inch PTD Personnel Transfer Device Qualified A person who, by possession of a recognized degree,

certificate, or professional standing, or who by extensive knowledge, training, and experience has successfully demonstrated the ability to solve or resolve problems relating to the subject matter.

RA Risk Assessment Radius of Load The horizontal distance from the centre of rotation to a vertical

line measured through the suspension point of a load on the hook; also known as the “operating radius”.

Reeving The passing of wire rope over sheaves, drums and pulleys. RM Routine Maintenance Rotation resistant rope

A wire rope consisting of an inner layer of strands laid in one direction covered by an outer layer of strands laid in the opposite direction. This has the effect of reducing the tendency of the finished rope to rotate by developing counteracting balance torques.

Running rope A rope which travels around sheaves or drums, as opposed to a standing rope or pendant line.

Safe Working Load (SWL)

The maximum load, as certified by a competent person, which an item of lifting equipment may raise, lower, or suspend under particular service conditions; the Safe Working Load can be lower than the Working Load Limit.

Side load A load applied at an angle to the vertical plane.

Signal Man The single individual who is responsible for giving directions to the crane operator. These directions may be via hand signals or radio communications; also known as the Banksman. API Hand Signals.

SIMOPS Simultaneous Operations. Slewing Commonly used offshore to describe swinging. See: Swinging SLI Safe Load Indicator



Sling A pre-assembled rope, chain or synthetic component for attaching a load to a lifting device and supporting that load in tension.

Snellen A particular type of vision (eye) test. Spreader Bar A strut type of structural member used in compression to

separate two static ropes or slings. SSLP Site Specific Lifting Procedure SSW Safe System of Work Standing (guy) rope

A supporting rope which maintains a constant distance between the points of attachment.

Superstructure The rotating upper frame structure of the machine and the operating machinery mounted thereon.

Swing Rotation of the superstructure for movement of loads in a horizontal direction about the axis of rotation; also known as ‘slew”.

Swing Gear External or internal gear with which the swing pinion on revolving superstructures meshes to provide swing motion; also known as “ring gear” or “bull gear”.

SWL Safe Working Load Tackle An assembly of ropes and sheaves arranged for lifting, lowering

or pulling. Tag line Rope, usually fibre, attached to load and used to control

horizontal movement, swinging or twisting of a load during a lift. Tailswing The horizontal distance from the centre line of rotation of a

crane to the maximum rear extension of the revolving superstructure; also known as “rear end radius”.

Telescoping boom

Consists of a base boom from which one or more boom sections are telescoped for additional length.

Temporary Is a modification to an approved system and or equipment for a specified time.

Test Certificate A certificate issued by the competent details of the test, or tests, and thorough examination conducted on each item of lifting equipment, certifying its fitness for safe use. The certificate must be retained for inspection when required.

Third Party A Company or persons who are hired in by the “Contractor” to carry out work for them under their contract with the “Parent Company”

Thorough Examination

An examination carried out by a competent person carefully and critically, and where necessary supplemented by other means such as measurement or non-destructive testing, in order to detect damage or deterioration.

Tonne Metric Ton (Te) Toolbox Talk A system of discussing and documenting the task ahead to

ensure all work parties understand what has to be carried out and including any potentional hazards.

Two-blocking The condition in which the hook block assembly comes in contact with the upper load block or boom point sheave assembly.

UV Ultra Violet Inspection Whipline A secondary rope system usually of lighter load capacity than

that provided by the main rope system. Working radius The horizontal distance from the centre of gravity of the load to

the crane’s centre of rotation. Also known as lifting radius.



Section 4 LEMS-04 System Documentation 4.1 Objectives

Introduction The objective of this “System” is to ensure that all employees both PCSB and Contract personnel understand the objectives of the LEMS. This is also to ensure that the system stays a “Living” or “Active” document. We will achieve this by defining the following: • Ownership, • Accountability, • Responsibility, • Reviews, • Changes.

4.2 Existing Procedures

4.2.1 Overview The LEMS Manual incorporates and renders redundant all previous directives related to lifting management system practices, procedures, and standards issued by PCSB. The Manual also incorporates other procedures which relate to operating, inspection and maintenance activities, and it complements and establishes a field level compliance with CIMG.

4.2.2 Current Practices and Standards Objective

Carigali Inspection & Maintenance Guidelines (CIMG),

DOSH Department of Safety & Health,

API Specification 2C Latest Edition,

API Recommended Practice 2D Latest Edition,

API Recommended Practice 9B Latest Edition,

API Specification 9A Latest Edition,

API Recommended Practice 8B Latest Edition,

ASME – B30.16 – Overhead Hoists Latest Edition,

ASME – B30.21 – Manually Lever Operated Hoists Latest Edition,

ASME – B30.9 – Slings Latest Edition,

ASME – B30.5 – Mobile Cranes Latest Edition,

ASME – B30.17 – Overhead Cranes Latest Edition,

ASME – B56.10 – Forklifts Latest Edition.



4.2.3 Site Specific Lifting Procedures (SSLP) Development

The LEMS provides the foundation and guidelines to develop procedures which are specific to PCSB locations. These procedures are called Site Specific Lifting Procedures (SSLPs) and end-users shall develop and keep them at the location as a SSLP Manual. Guidelines for developing SSLPs are included in Section 6 of this Manual.

4.3 Measurement

4.3.1 Purpose The objective of the LEMS is to provide an overview of safe operating procedures, instructions and guidelines for conducting routine and non-routine lifting operations at all PCSB locations without injury to personnel, damage to PCSB assets, threats to operational integrity or damage to the environment at all PCSB locations. Operations management is responsible for ensuring that these goals are met. This LEMS has been developed to contain the System documentation, and guidelines for the development of routine, non-routine and Site Specific Procedures. The Manual will be referred to as the LEMS Manual.

4.3.2 Activity Oversight All PCSB Location Supervisors, Safety Officers, Crane Operators and Technicians will monitor work progress for compliance to safety regulations and procedural requirements. PCSB Location Supervisors will provide guidance and interpretation of PSCB's regulations to both the PCSB and contract work teams. Location Supervisors will conduct informal checks on an ongoing basis on all procedures contained in this Manual to ensure that work activities meet all the approved conditions. The quality of the work effort and the equipment required for the job will be checked throughout the duration of the work. Training Required to Assist in Implementing the System: Personnel shall have sufficient experience, training and awareness to accomplish the program or activity and are familiar with applicable regulatory requirements, internal standards and guidelines.

4.3.3 Simultaneous Operations (SIMOPS) Location Supervisors will ensure that ongoing simultaneous operations and activities do not conflict with each other, from a safety and operations perspective.

4.3.4 Formal Non-Periodic Checks Location Supervisors will conduct formal checks and submit a report of the findings to the PTS upon the occurrence of two non-periodic events. These events are: • When a Full Proof Load Test (Section 10) is performed, • When a Lifting Incident Investigation (Section 14) is performed



4.3.5 Formal Periodic Checks

PCSB Operations Supervisor will conduct semi-annual formal checks and general assessments of a minimum of 50% of the procedures listed in Attachment 1 (Assessment Checklist), such that all "auditable" procedures will be assessed at least once per year. A report of the assessment findings shall be submitted to the cognizant PTS Manager, for review and comment. The PTS Manager shall then forward the report to the Asset Manager for review and action, as appropriate. The semi-annual Assessment Summary, shown in Attachment 2 (Semi-Annual Assessment Summary), details the specific procedures, which are checked for effectiveness, non-compliance, corrective actions taken, and recommendations for improvement.

4.3.6 Deviations and Non-Compliance Any unauthorized deviation from the safety regulations or an approved procedure requires immediate corrective action to be taken. Safety and procedural violations constitute unsafe acts and/or conditions and shall be reported to the Operations Supervisor for further investigation and disposition.

4.3.7 SSLP Reviews PCSB Operations Supervisors will also conduct formal checks of the Site Specific Lifting Procedures (SSLPs) developed for each location. The mechanism for these checks will be integrated with the testing and validation process, which will be developed for each SSLP. The frequency of the assessment will be decided after the completion of the SSLP Manual for each location.

4.3.8 Deficiencies Deficiencies detected during checks will be corrected instantly. Location Supervisors will review procedures with the work teams and the updating of the SSLP procedures will be performed on an "as needed" basis.

4.3.9 Audits Audit teams will conduct periodic assessments on the effectiveness of the System. Audit assessment reports on observations and recommendations will be reviewed with the System Manager and the System Custodian.

4.3.10 Custodian and Owner Assessment The System Custodian will assess the effectiveness of the System annually and the System Manager will review the results of the annual assessment. While the manager and custodian of this document is the PTS Head, the ownership is maintained by PD (GM).



4.3.11 Feedback

Each PCSB Platform Superintendent is responsible for forwarding the findings and the suggestions for improvement, as summarized in Attachment 2, to the LEMS System Custodian. This feedback will form the basis of the annual assessment of the System effectiveness. Feedback on the effectiveness of the System, practices and procedures is encouraged from all the end-users and may be submitted at any time. Attachment 3 (System Feedback Form) is included for end-users to forward their comments and proposals. The User and their respective Location Supervisors/Superintendent shall submit the System Feedback Form. The Operations Supervisor shall review and forward the original of the form to the PTS Manager, with a copy to the Asset Manager, MSG Superintendent, Asset Engineer, as appropriate.

4.3.12 Approval Authority The Custodian (PTS Manager) is the person designated to approve System procedures and changes with the exception of those that are Integrity Critical. The General Manager is the person designated to approve the System documentation and changes, including those that are Integrity Critical.

4.3.13 Training / Refresher Refresher training will be conducted as determined by each Operations Supervisor based on the employees' understanding and compliance to approved Site Specific Procedures. The System Custodian, in the annual assessment for LEMS effectiveness, will decide on the need for more general refresher training.

4.3.14 Control Copy The PTS Manager or the designated alternate will hold the master hard copy and the computer generated ‘CD’ of the LEMS Manual in the PCSB/KOP Office.

4.3.15 Update Frequency The LEMS Manual will be subjected to a general review by the System Custodian on an as and when required basis.

4.3.16 Review Frequency The System Manager will ensure a formal review of the LEMS Manual is carried out on a 3 yearly basis.

4.3.17 System Approval Frequency The PTS Manger will subject the LEMS Manual to re-approval, after a formal review of the System, on a 3 yearly basis. The first due review date will be determined by the initial issue date of the LEMS Manual. Subsequent due review dates will be determined by the date the previous review of the LEMS Manual was approved.



4.3.18 System Revision Process

The system revision process for making all changes to the LEMS System will be as follows: • All procedures recommended for change will be forwarded to the

custodian of the LEMS, on the approved "System Feedback Form," included in Attachment 3.

• The custodian of the LEMS manual will maintain a file, which details each recommended procedure change submitted.

• All recommended changes will be reviewed by the PTS Manager before being adopted. All changes relating to existing safety procedures require Asset Managers approval.

• When approval for any procedural change to the LEMS system has been granted by the required Asset management approval level, the custodian of the LEMS manual shall:

Update the master copy of the e-manuals for the LEMS manual to reflect the approved procedural change(s),

Arrange to have sufficient copies of the relevant page(s) in the LEMS manual, which are affected by the approved procedural changes, printed for distribution to all holders of the LEMS manual, in accordance with the LEMS manual distribution list,

Update the master hard copy of the LEMS manual to reflect the approved procedural change(s),

Forward the newly printed pages, accompanied by an appropriate document transmittal letter, to all holders of the LEMS manual, in accordance with the LEMS manual distribution list.

• Whenever approval for any procedural change to the LEMS manual has been granted by the Asset management approval level and that change affects the table of contents of the LEMS manual, the custodian of the LEMS manual shall arrange to have the table of contents revised, reprinted and distributed to all holders of the LEMS manual, in accordance with the LEMS manual distribution list.

• All holders of the LEMS manual will be responsible to update each assigned manual and to communicate the approved changes, received from the custodian of the LEMS manual, to their respective groups.

All holders of the LEMS manual will be responsible to update the "Revision Control Record" form, which is located at the front of each LEMS manual immediately upon updating the respective manual.



4.3.19 Management of Change

Reference: PCSB MOC Document - 1999 Work must be performed in accordance with approved procedures. Any changes to the LEMS System or to the procedures are governed by the Management of Change (MOC) procedures, included in Section 5. The “MOC” procedures for the LEMS covers: • Updating the LEMS, • Revising the LEMS, • Additions to the LEMS, • Corrections to the LEMS. The MOC procedures for the LEMS also define the administration for processing all changes to the LEMS. In any case where it is deemed necessary to intentionally not comply with pre-approved procedures relating to lifting and/or maintenance operations, the submission of a Management of Change is required.



4.4 Attachments

4.4.1 General

This section contains examples of report and feedback forms. The user should copy the attachment, (where applicable) with the copies filled out and forwarded as appropriate. Attachment 1 – Example of an Assessment Checklist Category – A Not Applicable.

Category – B Assess When Opportunity Arises.

Category – C Assess as per PCSB Requirements.

Category – D Record the Date of Assessment in the Appropriate Column.

SECTION CONTENTS CATEGORY 1ST HALF 2ND HALF

PCSB-LEMS-2004-00 Table of Contents A

PCSB- LEMS-2004-01-00

PCSB- LEMS-2004-01-01

PCSB- LEMS-2004-01-02

PCSB- LEMS-2004-01-03

PCSB- LEMS-2004-01-04

PCSB- LEMS-2004-01-05

Introduction

Purpose

Objective

Users

Responsibility

References

A

PCSB-LEMS-2004-02-00


Definitions

Abbreviations A



Record of Revision

List of Distribution A

PCSB- LEMS-2004-04-00

PCSB- LEMS-2004-04-01

PCSB- LEMS-2004-04-02

PCSB- LEMS-2004-04-03

PCSB- LEMS-2004-04-04

System Documentation

Objectives

Existing Procedures

Measurement

Attachments

A

PCSB- LEMS-2004-05-00

PCSB- LEMS-2004-05-01

PCSB- LEMS-2004-05-02

PCSB- LEMS-2004-05-03

PCSB- LEMS-2004-05-04

PCSB- LEMS-2004-05-05

PCSB- LEMS-2004-05-06

Management of Change

Introduction

Definitions and Scope

Change Type Requirements

Change Originator Requirements

Documentation and Process

Attachments

A

Note: The remainder of the sections will be added as they are completed



Attachment 2 – Example of a 3 Yearly Assessment Summary Use a separate sheet to summarise each LEMS. Elaborate the Yes/No answers in the remarks columns as required.

LEMS: Location: Date:

Circle either “Yes” or “No” below: Does this procedure meet the requirements of the task? Yes No

Should this procedure reside in a more appropriate manual? Yes No

Is this a frequently used procedure? (More than once per month?) Yes No

Are contractor personnel required to use this procedure? Yes No

Do all affected personnel demonstrate a full understanding? Yes No

Is there 100% compliance? Yes No

In the past 12-months, has there been an associated adverse incident? Yes No

Did this assessment raise any concerns with effectiveness, compliance, etc.?

Yes No

Remarks:

Platform Superintendent:

Signature:

Note: Forward to PTS Manager.



Attachment 3 – Example of a System Feedback Form System – Lifting Equipment Management System (LEMS). End users of the LEMS can, at any time, send their proposals and comments to the MSG Superintendent. The Superintendent will review all proposals and comments and determine if changes to the procedures and/or system are required. The MSG Superintendent will reply to the end user of the proposal by returning a completed copy of this form.

Note: Send this form directly to the MSG Superintendent.

Date:

Initiated by (Name):

Position:

Location:

Procedure Reference No:

Subject:

Proposed Change/reason for change:

Feedback:

Proposal accepted: Yes No

(Provide explanation for either accepting or rejecting the proposal)

Reviewed by Platform Superintendent:

Initial: Date:

Reviewed by PTS Manager:

Initial: Date:

Approved by MSG Superintendent:

Sign: Date:

Reference made to attached Job Hazard Analysis (JHA)



Section 5 LEMS-05

Management of Change

5.1 Introduction

This LEMS incorporates a process that provides for adoption of change. The objective of this guideline is to document and provide an overview of the various Management of Change procedures or systems that are currently available at PMO. The user shall refer to the actual procedures for detailed requirements before implementing the changes at any PCSB facility. Reference is made to: PCSB/PMO Management of Change Guidelines 01/10/1999.

5.1.1 Scope of MOC The MOC is established to manage the changes in a systematic manner so that all proposed changes are properly studied, reviewed and endorsed by all designated parties or authorities. It establishes the standards required to control hazards associated with change. Several procedures are already in place to cover the key requirements intended to address the PMO procedures for proper handling of a request to change and its implementation.

5.1.2 Types of Changes These changes include the changes in controlled documentation, process design information, plant equipment and organisation which can be listed as follows: • Permanent modification to plant and equipment, • Temporary modification to plant and equipment, • Change in process chemicals/additives, • Change in Technology, • Operations outside specified operating limits, • Changes in Operating Procedures Manual, • Changes in electrical classification, • Different material of construction, • Temporary connection including experimental equipment, • Organizational structural changes. Attachment 1: shows the table of various changes and their respective MOC. The custodian for each MOC in PMO is also specified.



Attachment 1: The matrix of the changes to their respective MOC

procedures and custodian. No. Description of Changes MOC

Procedure Custodian for PMO

1 Permanent modification to plant and equipment

FIP PTS 2

2 Temporary modification to plant and equipment

TAM PTS 2

3 Change in process chemicals/additives

MSDS PSE

4 Change in Technology FIP PTS 2 5 Operations outside specified

operating limits FIP PTS 2

6 Changes in Operating Procedures Manual

COPM Asset

7 Changes in electrical classification FIP PTS 2 8 Different material of construction FIP PTS 2

9 Temporary connection including experimental equipment

TAM PTS 2

10 Organizational structural changes. OSC PHR Abbreviations: FIP: Facility Improvement Procedure, TAM: Temporary Alteration/Modification Procedure, MSDS: Material Safety Data Sheet, COPM: Change of Operating Procedure Manual, OSC: Organizational Structure Change, 5.1.3 MOC System Overview

A fundamental aspect of MOC system is to ensure that a proposal for change is properly studied and reviewed, and that the recommendations for the proposed change are properly authorized by all designated authorities. These changes should also be formally documented for future audit trails. The level of review and authorization must commensurate with the risks and the significance of the changes. Basically the overall structure of MOC system has three (3) elements as shown in Attachment 2. The summary of the responsibilities of each party are outlined in Attachment 3.



Attachment 2 - Structure of MOC System

Attachment 3 - Summary of the Responsibilities Action Party Responsibilities Approval

Authority Originator • Identify the required changes

• Complete the relevant forms and submit with associated document to relevant approval authority

• Implement approved changes and associated follow up actions if appropriate

N/A

Designated Authorized Representative

• Has the overall responsibility for proper handling of all proposed changes

• Review, study the change request and/or work the details of the change request

• Make final decisions on the acceptability of a change request

• Ensure that all follow up actions from an approved change request are implemented in a timely manner

All the changes requested

Implementer • Formulate the required plan(s) for working the details of the change request

• Identify and/or initiate all documentation charges

N/A

ORIGINATOR

DESIGNATED AUTHORIZED

REPRESENTATIVEIMPLEMENTOR

Change Request

Approval

Document Changes



5.1.4 Feature of the MOC

The MOC procedure shall incorporate the following features: • A document system assuring the continued integrity of the installation, • Description and technical justification for the proposed change, • Originator and initial approval authority, • Duration of change if temporary, • Authorization requirements, • HSE reviews required before the change is implemented e.g. Hazard

Analysis, • Pre Start up HSE Study, • Final authorization prior to change implementation, • Updating of HSE and Process Design Information, • Updating of CIMAH written report, • Updating of safety case, • Tracking system so that all changes are easily referenced for future

review/audits.

5.1.5 Review and Audit of the MOC Upon acquisition or change in management control, a thorough review of existing management system should be carried out to determine how the facility can be incorporated into PCSB HSEMS. In addition, each MOC procedures shall be audited annually by the PSE manager. Any changes to HSE controlled documentation shall be authorized by the appropriate HSE committee.

5.1.6 Guideline Review The Technical Services Department (PTS) is the custodian of this guideline. The PTS HSEMS Task Force shall be responsible to coordinate the review process of this guideline annually and shall incorporate: • Revision of PCSB HSE Policy, • Results of HSEMS Audits, • Annual HSE Management review, • Revision of any MOC, • Customer feedback (and complaints), • Process improvement The review exercise should be part of the PTS annual HSE plan.

5.1.7 Reference 1. Management of Change Guidelines (MOCG) 1999, 2. HSEMS Manual, 3. Facility Improvement Procedure (FIP), 4. Material Safety Data Sheet (MSDS).



Section 6 LEMS-06 Site Procedures 6.1 Introduction

This LEMS recognizes and provides for the need to develop procedures specific to individual sites throughout PCSB. This chapter discusses the purposes, definitions and elements of the development and management of the SSLP’s. Overview The purpose of this section is to ensure that PCSB Supervisors and Superintendents are aware of the requirements contained within LEMS and to provide guidelines promoting compliance with those requirements and consistency in developing SSLP’s. LEMS Requirements LEMS (Operations and Maintenance), states that; "A system is in place which ensures the development of necessary operating, maintenance and inspection procedures and provides for updating at specified intervals and when changes are made." "A catalogued set of procedures includes all applicable regulatory requirements, company standards and policies, and site specific standards and work practices required for a safe operation of facilities."

Key Requirements for PCSB Development of SSLP’s There are a number of critical requirements that govern the development and management of the SSLP’s. These requirements are as follows: • Each SSLP must meet the expectations of LEMS. • Each SSLP must provide guidelines for routine and non-routine

specific tasks, • Each PCSB location will, with the assistance of the Crane & Lifting

Contractor, develop its own SSLP’s, when a generic procedure is not available or is unsuitable for a particular site usage,

• PCSB Supervisors and Superintendents will monitor the effectiveness of SSLPs on a continuous basis,

• PCSB, Superintendents and the PTS Manager, when applicable, shall monitor the development of SSLP’s on a continuous basis,

• The Maintenance Support Group Superintendent’s approval is required for all SSLP’s,

• All approved SSLP’s shall be contained in a dedicated manual, • Only approved SSLP’s will be used for training, • Testing and validation procedures shall be developed for each SSLP, • All Integrity Critical procedures in the SSLP manual will be reviewed

and updated every three years, and all non-integrity critical procedures in the SSLP manual will be reviewed and updated every five years.



SSLP Requirements Consistent with LEMS requirements, each location will have a set of specific procedures. These procedures will be compiled into a manual and the manual will be known as "Site Specific Lifting Procedures Manual." The objective of the manual is to provide the end-users at each site with a catalogued series of procedures to govern the performance of routine and non-routine site-specific tasks and thus ensure a safe and environmentally sound operation. All tasks shall undergo a task analysis and be classified as Integrity, Normal, or Work Aid. Procedures shall then be written considering the minimum required content. In addition, procedures shall, at a minimum, reflect consideration that: • All lifting appliances are certified, inspected, and maintained in

accordance with the applicable chapters of the LEMS. • All operators, signalmen/riggers, and other personnel participating in

the lifting and/or maintenance activities are trained and/or certified in accordance with the applicable chapters of the LEMS.

6.2 Definitions

Purpose This section defines a number of terms used throughout the document. Site specific lifting procedures SSLP’s are in 5 categories: 1. Routine integrity critical, 2. Routine non-integrity critical, 3. Non-routine, 4. Generic, 5. Specific. Routine activity A routine activity is defined as any work activity, which is usually performed for the normal operation and maintenance of a facility. Non-routine activity A non-routine activity is defined as any work activity, which is uncommon for the normal operation and maintenance of a facility. A non-routine activity will require a procedure that is developed by the end-user and review and approved by the appropriate management level, depending on risk and criticality, for use specifically to the site where the procedure was initiated.



Integrity critical activity An integrity critical activity is defined as any work activity, which is vital to the prevention of a major event on the facility, such as an uncontrolled emission, fire or explosion, which poses serious danger to people, property or the environment. Non-integrity critical activity A non-integrity critical activity is defined as any work activity, which is less vital but is necessary to maintain a safe and environmentally sound operation of a facility. Generic A generic procedure is defined as a procedure that is applicable to all sites and can be used as a reference throughout the field. Specific A specific procedure is defined as a procedure that has a special application, bearing, or reference to a specific site and generally cannot be used field-wide in its entirety.

6.3 SSLP Development Overview Purpose This section is on the development of the Site Specific Lifting Procedures. Site Specific Lifting Procedures LEMS requires each location to have an SSLP manual that will contain routine integrity critical, routine non-integrity critical and non-routine types of procedures. LEMS expectations further require that each site end-user shall have developed, reviewed, and obtained approval for procedures for its SSLP manual. Upon approval, these procedures will be included in the site’s SSLP Manual and will be kept for use at the respective site. Each site is to determine and develop procedures, with assistance from the Crane & Lifting Contractor, for inclusion in the SSLP manual. The developed list shall be submitted to the PTS for review and approval. Integrity critical procedures from the list will be identified for priority (refer to Attachment 1, Examples of IC Procedures, for examples of integrity critical procedures.)The procedure development will be prioritized and scheduled by each site and will be submitted for approval to the Maintenance Support Group Superintendent.



When to develop an SSLP A SSLP will be developed when a generic procedure is not available or is unsuitable for a particular site usage. These include but are not limited to: • Non-routine activities (e.g. a procedure for changing out a damaged

crane boom, etc.), • Routine integrity-critical activities (e.g. procedure for the emergency

lowering of a load.), • Routine non-integrity critical activities (e.g. prior to using lifting

equipment after a prolonged period of non-use, etc). SSLP Development Method Guidelines for development The following guidelines will be used when developing an SSLP: 1. Decide on the procedure that needs to be developed, 2. Decide on the type SSLP to be developed (integrity critical or non-

integrity critical), 3. Discuss the decision with the immediate supervisor, 4. Discuss and get assistance for drafting the procedure from the Crane

& Lifting Contractor, 5. Refer to the generic procedures and standards guidelines in this

LEMS Manual, where relevant, to develop each SSLP, 6. The supervisor will review the procedure and all modifications will be

made before the SSLP is put into effect, 7. Submit SSLP to the MSG Superintendent for approval, 8. Submit the SSLP to the relevant Operations Supervisor for approval

and include a copy of the approved SSLP in the SSLP Manual. Overall number sequencing A typical numerical sequence used for each SSLP will be as follows: AAAA/AAA – BBB/BBB – CCC – DDD E.g. PCSB/PMO – POD/DYG - 001 – 001 where: 1. AAAA/AAA -------- denotes the Company and Location 2. BBB/BBB ---------- denotes the Asset and Platform 3. CCC ----------------- denotes the section. 4. DDD ----------------- denotes the subject number, determined by the number of preceding subjects already allocated. Section grouping The section grouping of procedures (CCC) shall be categorized as follows: • Start up/Shut down procedures, • Isolation procedures, • Testing procedures, • Inspection/Maintenance Procedures, • Special Operations Procedures.



Measurement The measurement for the progress of SSLP development shall be done, on a continuous basis, both by the site and approved by the appropriate management level as outlined in the LEMS. Review and update When a procedure has been used for a specific task, once this task is complete, a review of the JHA should be carried out to ensure all risks have been eliminated as far as possible. Any amendments shall be documented. Training The training will only be carried out by fully qualified, competent personnel. Only approved procedures in the SSLP will be used for personnel training purposes on site.

6.4 Attachments General This section contains examples of Integrity Critical Procedures. Attachment 1 - Examples of Integrity Critical Procedures The following examples of Integrity Critical Procedures are furnished only to provide a sense of the nature and type of the procedures that are so categorised. Section Grouping Number 001: START UP/SHUTDOWN: • Crane normal start up • Crane normal shut down • Crane emergency start up • Crane emergency shut down Section Grouping Number 002: ISOLATION • Crane isolation for major job, i.e. overhaul • Crane isolation for routine job • Crane isolation for cleaning/inspection job Section Grouping Number 003: TESTING • Crane testing after overhaul • Testing of lifting equipment • Lifeboat davit testing Section Grouping Number 004: INSPECTION/MAINTENANCE • Vessel entry/inspections • Air conditioning maintenance • Crane structure maintenance/inspection • Winch components maintenance/inspection/overhaul



Section 7 LEMS-07 Lifting Equipment Standards 7.1 Introduction

The purpose of this chapter is to list the various types of lifting equipment subjected to the requirements of the LEMS.

7.2 General

7.2.1 Application This chapter applies to all PCSB locations.

7.2.2 Minimum Compliance As a minimum requirement, all lifting equipment in use by PCSB will comply with the requirements contained in: • CIMG – Carigali Inspection & Maintenance Guidelines, • HSEMS – Health, Safety & Environmental Management System, • DOSH – Department of Safety & Health, • API Specification 2C – Latest Edition, • API Recommended Practices 2D – Latest Edition, • API Recommended Practice 9A – Latest Edition, • API Specification 9B – Latest Edition, • API Recommended Practice 8B – Latest Edition, • ASME – B30.16 - Overhead Hoists – Latest Edition, • ASME – B30.21 – Manually Lever Operated Hoists – Latest Edition, • ASME – B30.9 – Slings – Latest Edition, • ASME – B30.5 – Mobile Cranes – Latest Edition, • ASME – B30.17 – Overhead Cranes – Latest Edition, • ASME – B56.10 – Forklifts – Latest Edition.

7.2.3 Lifting appliance Any machine which is able to raise, lower, or suspend a load (e.g. crane, forklift, powered hoist), including its attachments for anchoring, fixing, or supporting it (e.g. mono rails, beam trolleys, beam clamps, sheave blocks, winches, runway beams, and padeyes etc).

7.2.4 Lifting gear An item used to connect a load to a lifting machine that is not capable of providing any movement to lift or lower the load on its own.

7.3 Included Equipment

7.3.1 Purpose The following listed lifting equipment and associated lifting hardware and gear fall, under the requirements established in the LEMS.



7.3.2 Lifting equipment

All lifting equipment as follows: • Offshore Pedestal Mounted Cranes, • Survival Craft Launching Appliances, • Winches, • Forklifts, • Overhead Cranes, • Mobile Cranes, • Personnel Lifting Devices, • Powered/Manual Hoists, • Fixed Lifting Equipment, • Loose Lifting Gear. Note: All Tenders rigs, Jack ups etc are to adhere to the LEMS whilst

they are working for PCSB. Lifting appliances on all Tenders and Jack Ups will be inspected before being permitted onto a PCSB site.

7.3.3 Exceptions

Exceptions to the above requirements are governed by the Management of Change Procedures.

7.4 Excluded Equipment

7.4.1 General The following equipment does not fall under the requirements established in the LEMS: • Drilling Rig Draw-works • Work over Rig Draw-works

7.4.2 Exceptions Exceptions to the above requirements are governed by the Management of Change Procedures.



Section 8 LEMS-08 Rigging/Slinging Practices & Hoisting Equipment 8.1 Objectives

The lifting, rigging and slinging information given in the following pages will assist the crane operator, banksman, slinger or rigger to meet the following objectives: • With respect to lifting and slinging, know the mandatory requirements

set by law and be able to understand and work to the required standards,

• Be able to select the correct equipment and safely sling, in readiness for lifting, all types of loads encountered,

• Be able to understand and use preferred hand signals and radio instructions when working as a member of the deck crew,

• Be able to direct the crane operator to safely manoeuvre a load, especially when the load is out of sight of the operator.

DO NOT TAKE RISKS

• IF IN DOUBT ASK YOUR SUPERVISOR, • DISCUSS THE LIFT AS A TEAM BEFORE STARTING, • ALWAYS BE AWARE OF WHAT OTHER MEMBERS OF THE

TEAM ARE DOING.

8.2 Identification & Colour Coding of Equipment Identification Every item of lifting equipment, portable and fixed should be clearly marked with: • Identification Number, • Safe Working Load (SWL), • Colour Code. Safe Working Load (SWL) The maximum load or mass (as certified by a competent person) that an item of lifting gear may lift, lower or suspend under particular service conditions. The SWL of each piece of lifting equipment is permanently marked on the equipment. If the SWL of an item of lifting equipment cannot be read with certainty, that item SHOULD NOT be used. Working Load Limit (WLL) The maximum load or mass that an item of lifting gear is designed to raise, lower or suspend. Note: The Working Load Limit (WLL) is determined by the

manufactures, based on the mechanical properties of the item. The SWL is specified by a competent person based on the use to which the item will be put.



Colour Coding All lifting equipment is subject to a six (6) monthly inspection. Equipment that has been passed for further use is usually subject to some form of colour coding. The colour code in current use shall be prominently displayed on the platform and in the rigging loft on an indicator board similar to that shown below.

HOISTING/LIFTING EQUIPMENT COLOUR CODE

COLOUR

TRAVELLING BLOCKS, SLINGS, SHACKLES, PADEYES, PULL LIFTS, CHAIN BLOCKS, RUNWAY BEAMS, MONO RAILS ETC MAY ONLY BE USED WITH THE ABOVE COLOUR CODE

Note: The colour code strip will slide onto the board so that it can

easily be changed every 6 months. The most common colours to be use are: • Green • Yellow, • Blue. Any item of lifting equipment not bearing the current colour code SHALL NOT be used. Item found with the wrong colour should be removed from their location and be made ready for back loading to shore for inspection and re-certification. The colour red shall only be used to identify items that are not be used e.g. scrap. If extra equipment is to be used for one specific job and that job alone e.g. platform shutdown or wireline, then these items will have there own coding. This will be two-tone, i.e. orange and white strips. This will distinguish these items from all others at site and should only be used for that job. Only qualified, trained and competent personnel are to use lifting equipment.



8.3 Hoisting Equipment Maintenance

References are: API-RP 2D, API 8B, ASME B30.21 & B30.16. Objective The objective is to provide users of the equipment guidelines for inspection, maintenance and repair that may be utilized to maintain serviceability of the equipment in use. Qualifications Any inspection, maintenance and repair should only be carried out by personnel who are qualified by professional trade or are deemed competent and have the necessary skills and or knowledge as required. Documentation All equipment used should have a traceability system which may contain any of but not limited to the following: 1. Colour Coding, 2. Inspection Records, 3. Maintenance Records, 4. Information from maker, 5. ‘T’ card system to show where item is being used on the plant and

who removed the item from the rigging store? This allows all items to be traced when in use. Inspection Inspection Categories (a) Initial Inspection Prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to verify compliance with the applicable provisions of this volume. (b) Inspection Intervals Inspection procedure for hoists in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as frequent and periodic, with respective intervals between inspections. (1) Frequent Inspection Visual examinations by the operator or other designated personnel with records not required. (a) Normal service - monthly; (b) Heavy service - weekly to monthly; (c) Severe service - daily to weekly; (d) Special or infrequent service - as recommended by a qualified person

before and after each occurrence.



(2) Periodic Inspection Visual inspection by a designated person who makes records of apparent external conditions to provide the basis for a continuing evaluation. An external coded mark on the hoist is an acceptable identification in lieu of records. (A metal stamp mark shall not be made in a highly stressed area.) (a) Normal service - yearly; (b) Heavy service – semi-annually. If external conditions indicate,

disassembly should be done to permit detailed inspection, (c) Severe service - quarterly. If external conditions indicate, disassembly

should be done to permit detailed inspection, (d) Special or infrequent service - as recommended by a qualified person

before the first such occurrence and as directed by the qualified person for any subsequent occurrences.

Frequent Inspection (a) Frequent inspections shall be performed at intervals and shall include

observations during operation, (b) A designated person shall determine whether conditions found during

the inspection constitute a hazard and whether a more detailed inspection is required,

(c) The following items shall be inspected: (1) Operating mechanisms for proper operation, proper adjustment,

and for unusual sounds such as but not limited to binding noise of the chain, bearing squeal;

(2) Hooks for deformation and cracks etc, (3) Hook latches, if used, for proper operation; (4) Load chain, (5) Load chain reeving for compliance with the recommendations of

the hoist manufacturer or a qualified person; (6) Hoist lever for bends, cracks, or other damage, (7) Damage to the support for the hoist.

Maintenance These actions may include some of the following dependent on the repair required: 1. Adjustments, 2. Lubrication, 3. Cleaning, 4. Replacement of parts, 5. Testing. The above maintenance actions will be determined by some but not limited to the following: 1. Time in service since last repair, 2. Wear on any component, 3. Faulty equipment, 4. The environment, 5. Condition, 6. Untraceability of test certificates.



Repair Procedures Manufacturers should provide adequate inspection criteria to allow the equipment owner or user to identify the nature of repairs that may be required. If repairs are not performed by the manufacturer, they should be performed using methods or procedures that are established. Bearings Bearings play an important part in the serviceability of equipment. The most likely causes for bearing replacement are loose or bent cages (rolling element retainers), corrosion, abrasion, lubrication problems and spalling from fatigue. Internal clearance in excess of manufacturer’s allowance may indicate improper adjustment or assembly, which should be corrected. Repair of anti-friction bearing should not be attempted by field or shop personnel. Consultation with the equipment manufacturer is recommended in the event of unexplained or repeated bearing failure. Replacement Parts Replacement parts should meet or exceed the original equipment manufacturer’s (OEM) criteria. Procedure Development The owner and user together with the manufacturer should jointly develop and update inspection, maintenance, repair and remanufacture procedures consistent with equipment application, loading, work environment, usage, and other operational conditions. These factors may change from time to time as a result of new technology, equipment history, product improvements, new maintenance techniques and changes in service conditions. If the manufacturer of the equipment no longer exists or is unable for any reason to provide suitable recommendations, the owner or user should develop inspection, maintenance, repair and remanufacture procedures consistent with widely accepted industry practices.



8.4 Hoisting Operations

Safe use of Chain Blocks/Lever Hoists • Reference is made to ASME B30.16 & B 30.21, • Ensure the chain block and all associated equipment is of the correct

SWL for the task in hand, • Ensure the chain block load chain and hand chain are of the correct

length for the job and the load hook has enough height of lift (HOL), • Do not operate the block outside its maximum working range (SWL), • When using a block ensure that it can move freely and is not hindered

in the eye of the attachment, • After attaching the load ensure that the load and hand chains are

hanging freely, • Do not allow grit or grease to accumulate in the profiles of the hand or

load chain wheels, • Listen to the “clicking” of the ratchet pawl during use. If this cannot be

heard then there is a fault with the equipment and all operations must be stopped straight away,

• When a block is used within its operating range, it can easily be used by one person. If however this is not the case and excessive force is required then there is a problem, either with the block, the load is not free to lift or the weight of the item to be lifted is greater than the blocks capacity,

• After use the block should be cleaned and inspected before being put into the storage area. The hook should be raised and both hand and load chains wrapped around the load chain.

8.4.1 Block/Hoist Replacement

The following in-service inspection guidelines are provided for blocks/hoists. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects, which are noted, brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Evidence of wear, distortion, cracking, corrosion, due to misuse, or

other damage to any part of the block/hoist, • Elongated hooks, • Stretched chain, • Ineffective or missing safety latches, • Illegible markings.



8.4.2 Maintenance

Maintenance requirements for blocks/hoists are stringent. These consistent primarily of keeping the blocks clean, protected from corrosion and chemicals and ensuring the use of non-acidic lubricants. All blocks/hoists should be changed out every 6 months and be sent ashore for inspection and re-certification.

8.5 Rigging /Slinging Practices • Carry out a Job Hazard Analysis, Risk Assessment and a Toolbox

Talk prior to commencing the job. • This will include but not be limited to the following:

1. Site visit to familiarise all work party, 2. Item to be lifted, 3. Weight of item, 4. Any obstructions on the lift path, 5. Equipment to be used, 6. COG of the item, 7. Personnel understand the objective of the task.

• Ensure the correct permit is in place, • Select the correct hitch that will control and hold the load, • Attach the lifting slings above the COG, • Select the correct lifting equipment for the task, • Inspect prior to use, • Protect the slings from sharp edges, • Attach tag lines to the item to be lifted, • Keep all non essential personnel clear of the load, • Erect barriers around the lift area and from there to the final set down

point, • Lift the load clear of the deck and check all rigging, • Use clear and proper hand signals or radio, • Ensure the banksman is the only person carrying out the directions, • The banksman should be clearly identified by wearing a coloured bib

or hat, • Maintain complete control of the load, • Move the load to the decided location in a safe manner, • Keep the load as close to the ground as possible during the

movement of the load. See Attached Example of Job Hazard Analysis Form



8.6 Safe use of Wire Slings

• Reference is made to API-RP 2D & ASME B30.9 Slings.

8.6.1 Use of Slings

The guidelines below should be followed when using slings: • Use of wire slings should only be carried out by trained personnel, • Carry out a visual inspection of the slings prior to use, • Check the weight of the load to be lifted does not exceed the SWL of

the slings, • When using multi leg slings remember that the SWL is quoted for the

included angle at the master link of 0º to 90º, • Remember that the tension in the sling leg varies with the included

angle at the hook. A single angle is usually denoted by the included angle at the lifting points, which is: a) Two leg slings, the angle between the sling legs, b) Three leg slings, the angle between one leg and the vertical (0º to

45º) c) Four legged slings, the angle between any two diagonally opposite

legs. • Care must be taken to ensure not to “Kink” a sling. A kink in a sling will

distort the sling, severely affecting its strength and will need to be removed from service and destroyed. Kinks are usually formed in one of two ways: a) Bad slinging practise, e.g. tensioning a sling over an acute angle

or round to small a diameter, b) By pulling on a loop accidentally formed in a sling.

• Under no circumstances should two slings be joined together by threading the eyes of the slings. They should be joined by a shackle of at least the same SWL as the slings to be joined,

• Always avoid bending a sling around a small diameter. The minimum radius around which a sling should be bent is 6 times the rope diameter,

• Always avoid bending slings around sharp edges. It could damage the sling and reduce the SWL of the sling. Use wood as packing around the sharp edges, this generally increases the radius around which the sling is bent,

• Proper storage shall be provided for slings while not in use. • Slings shall never be choked in the splice, • Loads shall not be lifted with one leg of a multi-leg bridle sling until the

unused legs are secured, • Any angle other than vertical at which a sling is rigged increases the

loading on the sling, • Whenever a sling is found to be deficient, the eyes must be cut, or

other end attachments or fittings removed to prevent further use, and the sling body discarded,

• A sling eye should never be used over a hook or pin with a body diameter larger than the natural width of the eye. Never force an eye on a hook. The eye should always be used on a hook or pin with at least the diameter of the rope,



• Rated loads of a sling are different for each of the three basic methods

of rigging (vertical, choker, basket, etc.) and the rated loads of a sling are different for each of the methods of rigging based on construction of the wire rope, web material and width, etc. These rated loads are available from the manufacturers. These rated loads will be indicated on the heavy duty tags attached to each type of sling at the time it is fabricated.

8.6.2 Sling Replacement

The following in-service inspection guidelines are provided for wire rope slings. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects, which are noted, brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Evidence of wear, distortion, cracking, corrosion, discoloration due to

heat, or other damage to any part of the sling, • Evidence of movement at splices or ferrules, • Broken or cut wires, • Kinks (some permanent setting due to previous use around a load is

acceptable, but a careful check for other local damage should be conducted),

• Protrusion of the core, • Ineffective or missing safety latches, • Illegible markings.

8.6.3 Maintenance Maintenance requirements for wire rope slings are minimal. These consistent primarily of keeping the slings clean, protected from corrosion, and ensuring the use of non-acidic lubricants. All wire slings up to 10MT shall be sent ashore and inspected every 6 months and dependent on the findings, replaced if necessary. Slings above 10MT shall not be kept offshore and shall be sent offshore with that particular heavy lift.



8.7 Flat Woven Webbing Slings 8.7.1 Safe Use of Flat Woven Webbing Slings

• Reference is made to ASME B30.9 Slings. • The following guidelines are provided for the safe use of flat woven

webbing slings: • Use of Fibre slings should only be carried out by trained personnel, • These slings are difficult to examine by visual means as chemical or

stress damage may be difficult to detect in the weave of the sling, and as a consequence extra care needs to be taken when carrying out pre use inspections,

• Extra attention should be given to Fibre Slings when inspecting for damage. Look for cuts, abrasions and possible contamination to the outer covers and stitching,

• Chemical attack on the sling can be recognised by weakening or softening of the material in the sling surface,

• Always protect the sling when passing it around items that may cause damage to the sling,

• Do not allow the slings to come into contact with hot materials as heat can adversely affect the sling. The maximum and minimum Temperatures are: above 80° C or below 0°C,

• Under no circumstances should two slings be joined together by threading the eyes of the slings. They should be joined by a shackle of at least the same SWL as the slings to be joined,

• Ensure the correct colour code is on the sling prior to use.

8.7.2 In-service inspection The following in-service inspection guidelines are provided for flat woven webbing slings. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not listed below that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects, which are noted, brought to the immediate attention of a competent person. Defects to note include, but are not limited to: • Damaged, chaffed or cut webbing, • Damaged or loose stitching, • Heat damage, • Chemical damage, • Solar degradation, • Damaged or deformed end fittings, • Illegible markings.

8.7.3 Maintenance Maintenance requirements for webbing slings is minimal and consist primarily of keeping clean with clean water and being allowed to dry naturally. All slings up to 10MT should be changed out every 6 months. Note: NEVER USE CHEMICALS TO CLEAN WEBBING SLINGS AS THIS WILL ATTACK THE FIBRES AND STITCHING



8.8 Round Slings 8.8.1 Safe use OF Round Slings

• Reference is made to ASME B30.9 Slings, • The following guidelines are provided for the safe use of round slings:

Round slings are to be checked prior to use and defective slings

are not permitted to be used, Ensure the sling engages correctly with fittings and the lifting hook

and ensure that smooth radii are formed which allow for the sling to assume its naturally flattened form under load,

Ensure that slings are not twisted or crossed and fittings are not overcrowded,

Chemical attack on the sling can be recognised by weakening or softening of the material in the sling surface,

Ensure the use of packing to protect the sling from sharp edges, It is not permitted to lift on the point of any hook, It is not permitted to shorten, knot, or tie round slings, Ensure that the slings are never exposed to direct heat or flames, It is not permitted to use round slings with cut or damaged covers

which is an indication that the integrity of the sling has been compromised,

Ensure the correct colour code is on the sling prior to use.

8.8.2 In-service inspection The following in-service inspection guidelines are provided for round slings. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects, which are noted, brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Damaged or cut outer cover, • Damaged stitching, • Exposed inner core, • Heat damage, • Chemical damage, • Solar degradation, • Illegible markings.

8.8.3 Maintenance

Maintenance requirements for round slings are minimal and consist primarily of keeping clean with clean water and being allowed to dry naturally. All slings up to 10MT should be changed out every 6 months.

Note: NEVER USE CHEMICALS TO CLEAN ROUND SLINGS AS

THIS WILL ATTACK THE FIBRES AND STITCHING



8.9 Hooks, Shackles, and Other Hardware

8.9.1 General

8.9.1.1 Selection

Special requirements for hooks, shackles, eyebolts, turnbuckles, links, and rings shall be addressed during the lift planning process and documented within the lift plan.

8.9.1.2 Use and Safety precautions Lift planners, riggers, and work leaders must be familiar with lifting gear, good rigging practices, load limits, and the use of load tables for determining safe work load limits for various rigging configurations.

8.9.1.3 Routine inspection, testing, and maintenance Hooks, shackles, and other hardware shall be inspected, tested, and maintained in strict compliance with the referenced regulations and industry standards, manufacturer’s recommendations, and facility requirements. For routine user/custodian inspections, the following guidelines shall be observed: • Users of hooks, shackles, and other hardware shall make a pre-use

visual check to ensure that the equipment is in good condition, fit for intended use, and current regarding applicable inspection intervals. Defects shall be reported to the crane operator and work leader to determine whether they constitute a safety hazard and whether a more detailed inspection is required,

• Equipment returned to storage shall be cleaned, inspected, and lubricated (as appropriate) after inspection. The routine inspection shall check for signs of wear, distortion, or other damage,

• All hooks, shackles, and other hardware shall be inventoried and visually inspected monthly.



8.9.2 Hooks 8.9.2.1 Inspection, testing, and maintenance

For the programmed testing and inspection of hooks, the following general guidelines shall be observed: • All hooks (excluding grab hooks) shall be equipped with safety

catches, • Inspection procedures and record keeping requirements for hooks in

regular service shall be determined by the kind of equipment in which they are used. When such requirements for hooks are stated in standards for the specific equipment they shall take precedence over the requirements of this section,

• The hook manufacturer or other certifying entity shall proof test all new and repaired hooks prior to initial use to ensure compliance with the recommended standard. Proof test certification and inspection records shall be kept for the life of the hook,

• Hooks shall undergo an inspection semi-annually, and at the discretion of a third party inspector, shall also undergo a non destructive examination according to applicable standards and be inspected for deformation, throat opening, safety latch operability, wear, and cracks. More frequent inspections should be scheduled for heavy or severe service situations.

• No periodic load testing of hooks is required except as necessary to conform to the requirements for the slings or rigging hardware of which they are a part.



8.9.3 Safe Use of Shackles 8.9.3.1 Safe Use Practises

The following guidelines are provided for the safe use of shackles. In that this is a general list, location or task specific precautions for safe and prudent use may not necessarily be included. The user is encouraged to consider elements not listed below that may further enhance operational safety: • Check the shackles before use and ensure that defective shackles are

not used. In particular, ensure the pin is the correct one in terms of type, fit and grade of material,

• Select the type of shackle and pin most suitable to the application, • Ensure that shackles are fitted so that the body takes the load along

its center line and is not subjected to bending, • Ensure that when connecting several sling legs, they are positioned in

the bow of the shackle to avoid forces that tend to spread the shackle jaw,

• Ensure the pin is screwed fully into the shackle eye, • Check that the thread is fully engaged with the body, but is not so long

that tightening causes the body to deform, • With bolt and nut type pins, ensure the nut jams on the inner end of

the thread and not on the eye of the shackles. The bolt should be free to rotate with minimal side float. The split cotter pin must be fitted before making a lift,

• Avoid applications where movement can unscrew the pin e.g. when used with a sling in choke hitch. Position the pin away from the moving part or use a nut and bolt type pin, which can rotate without unscrewing,

• Never replace the pin with a bolt, • If the shackle is PCSB owned, ensure colour-coding is current and the

I.D. No/Plant Number and the SWL are legible.

8.9.3.2 In-Service Use The following in-service inspection guidelines are provided for shackles. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. Consider elements not listed below that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects noted brought to the immediate attention of a competent person. Defects to note include, but are not limited to: • Distorted, worn, stretched or bent body or pin, • Damaged or incomplete thread forms, • Nicks, gauges cracks, or corrosion, • Incorrect pin, • Illegible markings.

8.9.3.3 Maintenance Maintenance requirements for shackles are minimal and consist primarily of keeping them clean, protected from corrosion, and the threads free of debris. All shackles up to 10MT should be changed out every 6 months.



8.9.4 Eyebolts 8.9.4.1 Safe use practices

The following guidelines are provided for the safe use of eyebolts. In that this is a general list, location or task specific precautions for safe and prudent use may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance operational safety. • Check the eyebolts before use - do not use a defective eyebolt. • Always check the thread of both the eyebolt and hole, ensure they are

compatible, fully formed, of sufficient length, undamaged and clear of any debris which may prevent proper engagement.

• Ensure the contact surface around the hole is flat, clean, perpendicular to the thread axis and big enough to support the entire eyebolt collar.

• Tighten the eyebolt down firmly by hand. The collar must sit evenly on the contact surface. Never use tommy bars, grips or wrenches to tighten eyebolts.

• With collar eyebolts used in pairs, ensure that both the eyes are in the same plane. Using shims is acceptable, but not machining the collar or over tightening.

• A hook of similar capacity must be engaged directly into the eye of a dynamo eyebolt or link of an eyebolt with link. Collar eyebolts must be fitted with a shackle or link to accept hooks. The hooks must move freely and are not permitted to be wedged or forced into position.

• Never reeve a sling through the eye links or shackles fitted to eyebolts used in pairs as this will impose a severe resultant force onto the eyebolts.

• Dynamo eyebolts are only suitable for axial loading. Never use dynamo eyebolts for angular loading

• When using eyebolts with multi leg slings, use eyebolts with links or collar eyebolts taking care to de-rate them for angular loading.

• Where a single eyebolt is used, use a swivel or swivel hook to prevent the eyebolt unscrewing if the load rotates.

• If the eyebolt is PCSB owner, ensure colour- coding is current if applicable and the I.D./Plant Number and SWL are legible.

8.9.4.2 In-service inspection

The following in-service inspection guidelines are provided for eyebolts. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects noted brought to the immediate attention of a competent person. Defects of note include, but are not limited to:

Any sign of distortion to the eye shank or link, Worn, damaged or incomplete threads, Nicks, gouges cracks and corrosion, Illegible markings.



8.9.4.3 Maintenance

Maintenance requirements for eyebolts are minimal and consist primarily of keeping them clean and protected from corrosion and thread damage. It is not permitted to attempt to straighten bent eyebolts or re-cut thread. All eye bolts should be changed out every 6 months and be sent ashore for inspection and re-certification.

Types of Eye Bolts



8.9.5 Turnbuckles 8.9.5.1 Safe use practices

The following guidelines are provided for the safe use of turnbuckles. In that this is a general list, location or task specific precautions for safe and prudent use may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance operational safety: • Check the turnbuckles before use - do not use a defective turnbuckle, • Select the type of turnbuckle and end fitting most suitable for the

application, • Ensure when the turnbuckle is used in an application where vibration

is present, it is extremely important to lock the end-fittings to the frame or body to prevent them from unscrewing and possibly releasing the load,

• If the turnbuckle is PCSB owner, ensure the color- coding is current if applicable and the I.D./Plant Number and SWL are legible.


The following in-service inspection guidelines are provided for turnbuckles. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects noted brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Worn, stretched or damaged threads, • The eye or hooks are worn or stretched, • The clevis pin or pin holes are worn or stretched, • Illegible markings.

8.9.5.3 Maintenance Maintenance requirements for turnbuckles are minimal and consist primarily of keeping them clean, well lubricated, and protected from corrosion and thread damage. All should be thoroughly inspected prior to use.



8.9.6 Plate Clamps 8.9.6.1 Safe use practices

The following guidelines are provided for the safe use of plate clamps. In that this is a general list, location or task specific precautions for safe and prudent use may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance operational safety: • Check the clamp before use- do not use a defective plate clamp, • Ensure that the clamps are suitable for the thickness of plate to be

lifted. Never exceed the maximum or minimum thickness for which the clamps are designed,

• Put the clamp onto the plate as far at it will go, • Do not use clamps at an angle to the edge of the plate or for lowering

from vertical or horizontal or vice versa, unless they are designed for that purpose,

• Keep oil grease and similar contaminates away from jaws which use a friction grip material to hold the plate,

• Never us the plate clamps on hard or polished plate unless they have been specifically designed for that purpose,

• Take great care to ensure the plate is fully supported before attempting to release the clamp,

• Keep all persons clear of the danger zone and remember that a falling plate can glide sideways,

• A large thin plate is likely to glide further. Also, the greater the height it falls from, the larger the danger zone,

• If the plate clamp is PCSB owned, ensure the colour- coding is current where applicable and the ID/Plant Number and SWL are legible.


The following in-service inspection guidelines are provided for plate clamps. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects noted brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Wear, damage, or distortion to fixed and moving jaws, • Frame opening bent out or cracked, • Insecure, worn, or bent pins, bolts, etc., • Worn friction grip material, • Damaged, bent, or unsatisfactory locking lever, • Tight, bent, or damaged clamping threads, • Corrosion, • Illegible markings.

8.9.6.3 Maintenance Plate clamps should be cleaned and any moving parts lubricated at appropriate intervals, unless the supplier's specific instructions indicate otherwise. For clamps with smooth jaws lined with a friction material, care must be taken to ensure no lubricate comes into contact with the friction material. Teeth of jaws must not be re-sharpened or re-cut unless the manufacturer has specifically approved this.



8.10 Lifting Beams and Frames 8.10.1 Safe use practices

The following guidelines are provided for the safe use of lifting beams and frames. In that this is a general list, location or task specific precautions for safe and prudent use may not necessarily be included. The user is encouraged to consider elements not listed below that may further enhance operational safety: • Check the lifting beams and frames before use – do not use a

defective beam, • Many lifting beams are designed for a specific purpose and are not to

be used for other purposes unless first consulting with the manufacturer. This consideration includes the size of the crane hook from which they are to be suspended,

• The weight of the beam, together with the attachments, must be added to the weight of the load when calculating the total load that will be imposed on the hook. The self-weight should be clearly marked on the beam,

• Ensure that the SWL on the lifting points is not exceeded. Extra care is needed where these points are adjustable or where there is a choice of lifting points,

• Ensure that the load remains stable and that the beam remains at its intended attitude during use,

• Particular care is required if the lifting points are below the centre of gravity of the load,

• Use tag lines to control long loads, • Do not permit the beam to foul the undersides of the crane or any

other obstructions when raising or transporting loads, • If the plate clamp is PCSB owned, ensure the colour-coding is current

where applicable and the ID/Plant Number and SWL are legible.

8.10.2 In-service inspection

The following in-service inspection guidelines are provided for lifting beams and frames. In that this is a general list, location or task specific inspection activities brought about by special application or employment conditions may not necessarily be included. The user is encouraged to consider elements not below listed that may further enhance the inspection process and component life. The inspection activities should be conducted regularly and any defects are noted brought to the immediate attention of a competent person. Defects of note include, but are not limited to: • Beam distorted, damaged, or corroded, • Worn, loose, or missing bolts or cracked welds, • Attachment points worn, damaged, or distorted holes and eyes worn

or elongated, • Illegible markings.

8.10.3 Maintenance

Maintenance requirements for lifting beams and frames are minimal and consist primarily of ensuring that bolted joints are sound and damage from corrosion is prevented. Refer to individual maintenance requirements for associated loose gear and attachments. Load testing should be carried out every year.



8.11 Safe use of Wire Ropes

• Reference and guidance is applied in API-RP 2D & API 9A. • The replacement criteria as per API-RP 2D Appendix G is, but not

limited to the following:

1. Running Ropes used in Boom Hoist: a) Six (6) randomly distributed broken wires within one (1) lay length, (See Fig. G2 below) b) Three (3) broken wires in one strand within one (1) lay length.

2. Running Ropes of Rotation Resistant Construction used on the Main and Auxiliary hoist: a) Four (4) randomly distributed broken wires within one (1) lay length, b) Two (2) broken wires in one strand within one (1) lay length.

3. Standing Ropes such as Pendants:

a) Three (3) broken wires within one (1) lay length, b) Two (2) broken wires at the end connection.

4. One (1) valley break may indicate internal loop damage requiring close

inspection of this section of rope. a) When two (2) or more valley breaks are found in one (1) lay length the

rope should be removed from service.

• All wire ropes shall be replaced and installed with the same specification as per Crane OEM, Qualified Source, Crane Contractor and or Wire Rope Manufacturer,

• Refer to the following API-RP 2D Section 5, 5.1.4d.

1. To avoid introduction of twist into the rope while reeving, remove the rope from the same side of the reel as it will be operated on the drum, top to top or bottom to bottom.

2. Spool rope under tension to properly seat the rope on the drum.

Particular care shall be taken in spooling the first layer. 3. Care shall be taken to assure that the boom, main and auxiliary hoist

systems reeved for the specific crane configuration in use. 4. When reeving through the sheave system, avoid kinks or looping

which could damage the rope. 5. Cut off all welded ends of the rope before installing in a wedge socket

or wedge in the drum.



6. Swivels shall not be used at the dead end of multi-part hoist systems

with rotation-resistant rope. 7. Swivels shall be installed at the dead end of single part systems

following the recommendation of the crane and/or wire rope manufacturer. The swivel is typically an integral part of the overhaul ball and may be of a top or bottom swivel design.

8. New rope, when first installed, shall be broken in by slowly lifting and

lowering a light load several cycles through the entire hoist mode. NOTE: Purchasing of the new rope shall be done through the Crane &

Lifting Contractor as part of their contract.

Factors Affecting Rope Performance Multi-coiling of the rope on the drum can result in severe distortion in the underlying layers. Bad coiling (due to excessive fleet angles or slack winding) can result in mechanical damage, shown as severe crushing, and may cause shock loading during operation. Small diameter sheaves can result in permanent set of the rope, and will certainly lead to early wire breaks. Oversize grooves offer insufficient support to the rope leading to increased localised pressure, flattening of the rope and premature wire fractures. Grooves are deemed to be oversize when the groove diameter exceeds the nominal rope diameter by more than 15%. Undersize grooves in sheaves will crush and deform the rope, often leading to two clear patterns of wear and associated wire breaks. Excessive angle of fleet can result in severe wear of the rope due to scrubbing against adjacent laps on the drum. Rope deterioration at the Termination may be exhibited in the form of broken wires. An excessive angle of fleet can also induce rotation causing torsional imbalance. The continued safe operation of lifting equipment, lifting accessories (e.g. slings) and other systems employing wire rope depends to a large extent on the operation of well programmed periodic rope examinations and the assessment by the competent person of the fitness of the rope for further service. Examination and discard of ropes by the competent person should be in accordance with the instructions given in the original equipment manufacturer’s handbook. In addition, account should be taken of any local or application specific Regulations. The competent person should also be familiar, as appropriate, with the latest versions of related standards such as API RP 2D & API 9A - code of practice for examination.



Particular attention must be paid to those sections of rope which experience has shown to be liable to deterioration. Excessive wear, broken wires, distortions and corrosion are the more common visible signs of deterioration (see below). Wear is a normal feature of rope service and the use of the correct rope construction ensures that it remains a secondary aspect of deterioration. LUBRICATION may help to reduce wear. Broken wires are a normal feature of rope service towards the end of the rope’s life, resulting from bending fatigue and wear. The local break up of wires may indicate some mechanical fault in the equipment. Correct lubrication in service will increase fatigue performance. Distortions are usually as a result of mechanical damage, and if severe, can considerably affect rope strength. Visible rusting indicates a lack of suitable lubrication, resulting in corrosion. Pitting of external wire surfaces becomes evident in some circumstances. Broken wires ultimately result. Internal corrosion occurs in some environments when lubrication is inadequate or of an unsuitable type. Reduction in rope diameter will frequently guide the observer to this condition. Confirmation can only be made by opening the rope with clamps or the correct use of spike and needle to facilitate internal inspection.



8.12 Slinging Angle Information

At SWL = 0° SWL of one sling x 2

30° SWL of one sling x 2 x 0.966




In addition to sling angle, an additional factor, which requires consideration, is the Mode Factor, as is illustrated in the following figures.

Mode Factor 1

Straight pull M = 1.0

Chokehitch

M = 0.8

Basket hitchM = 1.4(90° Maximum)

Basket hitchparallelM = 2.0

90°

60°

1.0 MT each sling 0.7 MT each sling

0.58 MT each sling

0.53 MT each sling

0.5 MT each sling

30°

1 MT load

120°



Mode Factor 2

Mode Factor 3

To determine the configuration-specific SWL, multiply the SWL of one leg by the Mode Factor “M”. Note that if slings are used with a choke or reeving hitch, the angle at the bight must be considered.

Straight pull M = 2.0

Chokehitch

M = 1.6

Basket hitchM = 2.8

(90° Maximum)

Basket hitchParallelM = 4.0

Two-leggedsling

M = 1.4(90° Maximum)

Four-legged sling

M = 2.1 (90° Maximum)



8.13 Slinging of Tubulars 8.13.1 General

The slinging of tubular is a very common lifting operation. Slings ideally should be positioned approximately 25% (of the total length) in from either end. This practice significantly reduces sagging of the tubular to a minimum.

8.13.2 Wrapping

Slings should be double-wrapped with a choke hitch, taking care not to cross over the wires on the underside of the pipe or tubular bundle. The choke hitch should be pulled tight to secure the bundle and a bulldog grip should be fitted. A tie wrap should also be fitted to prevent the reeved eye from slipping over the bulldog should the bundle loosen in transit.

This type of hitch compresses the load and prevents it from slipping out of the sling. Each sling should have a SWL approximately equal to the gross weight of the load. With respect to the bulldogs, only DIN 1142-type bulldogs are permitted for this use and, in order to prevent damage to the wire rope, personnel shall ensure that bulldog grips are not over tightened.

Fit with the threadedportion to this side.



8.13.3 Bundles

Care should be taken when releasing bundle slings, as individual tubes are likely to roll. In addition, the landing site should always be prepared so that the bundles may be landed without crushing the slings.

8.13.4 Stacking

When tubulars are to be stacked, personnel shall ensure that timber packing or a similar material is inserted so as to prevent damaging the slings.



8.13.5 Other Concerns

When slinging cargoes, ensure to never sling tubes of different diameters

When slinging cargoes, ensure to never sling a mixture of tubulars, angle, flat bars, etc, which will in all cases result in the smaller items slipping out.

Different diameter piping

Flat stock

Angle iron

Piping/tubulars



When slinging cargoes never tighten the choke by hammering as this will increase the effective sling angle, resulting in a weakening of the sling.

8.14 Protection of Slings & Loads

8.14.1 Protection of Slings

Irrespective of the sling material (wire, chain, or fibre), it is imperative to avoid bending the sling around sharp corners or edges. This will severely weaken the sling and often result in sling failure. Suitable packing should be used to prevent this situation from occurring.

Webbing slings

Timber strips

Timber strips

Web sling

Plate stock

Web sling

Cargo withsharp corners



8.14.2 Protection of Loads

Apart from protecting the lifting slings, it is the nature of certain loads that they require protection from the slings. In most cases where polyester slings cannot be used, timber packing is often suitable.

8.15 Selection and Labelling of Slings

8.15.1 Sling selection is an integral part of the lift planning process. Slings shall be selected to ensure they are not loaded beyond the manufacturer's recommended safe working loads and are applied so that they are within the working load limits specified in the applicable loading tables from the manufacturer or the referenced standards. Lift planners, riggers, and work leaders involved in rigging should be knowledgeable regarding sling types, sling applications and limitations, and applicable regulatory requirements and industrial standards. The use of natural or synthetic rope shall be avoided for rigging crane loads.

8.15.2 All slings must have durable and legible labels, permanently affixed by the

sling manufacturer. The labels shall contain the following information as guided by ASME B30.9 requirements:

Type of Sling Labelling Requirements Chain Sling Name, symbol, or trademark of manufacturer

Chain grade and size Rated load and angle on which it is based Colour Coding

Wire Rope Name, symbol, or trademark of manufacturer Rated load for the type of hitches and angle basis Diameter or size Colour Coding

Synthetic Web Name, symbol, or trademark of manufacturer Manufacturer’s code or stock number Rated load for the type of hitches and angle basis Type of material and construction Colour Coding

Synthetic Round (endless) Sling

Name, symbol, or trademark of manufacturer Manufacturer’s code or stock number Rated load for the type of hitches and angle basis Type of material and construction Cover material if different from core material Colour Coding



8.16 Safe Use of Equipment

8.16.1 General

Slings require special attention and caution in field applications because they are almost always subjected to severe wear, abrasion, impact loading, crushing, kinking, or overloading. Rigging personnel must be competent and knowledgeable in the proper use of slings. In addition to determining which slings to use, rigging personnel must determine further working load limit reductions as typically effected by the following factors: • Splicing, • End connections, • Type of hitch, • Angle of loading, • Centre of gravity of the load, • Diameter of curvature of the load.

8.16.2 General Inspection, Testing, and Repair

Inspection, testing, and repair Slings shall be inspected, tested, and maintained in strict compliance with the guidelines of the references below: ASME B30.9 “Slings” Inspection and Repairs:

Chapter 9-1, "Alloy steel chain slings" Chapter 9-2, "Wire rope slings" Chapter 9-5, "Synthetic webbing slings" Chapter 9-6, "Synthetic round (endless) slings"

A summary of requirements follows: Type of Sling

Chain Wire Rope Synthetic Web

Synthetic Round

Frequent Inspection

Pre-use (visual check)




Periodic Inspection

Semi-annually if in regular use (visual documented inspection) or sooner based on severity of use factors

Semi-annually if in regular use (visual documented inspection) otherwise at least annually

Semi-annually if in regular use (visual documented inspection)

Semi-annually if in regular use (visual documented inspection)

Missing or illegible label Removal criteria Worn links or

links with nicks and gouges exceeding allowable wear limits

Number, distribution, type of visible damaged wires.

Broken wire or edge, corrosion, distortion, end fittings

Visible damage (physical wear, corrosion, heat, chemical, burn, holes, tears, cuts, snags, stitching, knots, kinks, broken fibers) and any other doubts as to strength of sling or end fittings

NOTE: Refer to the above specific ASME chapter references for detailed information concerning elements of frequent and periodic inspections as well as removal criteria.



8.17 Winches 8.17.1 Introduction

This section describes the PCSB requirements related to the selection, maintenance, and inspection of winches.

8.17.2 Selection Criteria

When selecting a winch, the most important consideration is the required line pull. It must be kept in mind that the majority of manufacturer's line pull ratings are based on half drum performance, and this line pull decreases as the winch drum fills up. For example, Full Drum provides maximum speed and minimum-pulling force, Half Drum provides medium speed and medium pulling force, and First Wrap provides minimum speed and maximum pulling force.

NOTE: Half drum rating establishes average performance only. Do not

confuse this rating with wire rope capacity, which is approximately 36% of full drum storage at this point. For example, if a drum at full capacity can hold 100 meters of wire rope, at half drum, there will 36 meters on the drum. The next consideration is the drum capacity with respect to how much wire rope is required for the operation. The rope should, at a minimum, be of such a length that at the extreme position, at least five turns remains on the winch drum. This is to avoid any load being transferred to the rope anchor, which is not a load-bearing component.

8.17.3 Personnel use

On offshore drilling rigs or platforms, winches are often used on the drill floor for the hoisting and lowering of personnel. These winches will have been specifically designed or modified, certified and marked accordingly. No other winch should be used for transporting personnel.



8.17.4 Inspection and Maintenance 8.17.4.1 Pre-use Inspection

Prior to using the winch, the followings checks should be carried out: • SWL is adequate for the load, • Colour coding, if applicable, is current and the winch has a Equipment

Tag Number, • Examine the wire rope guard and ensure there is no damage /

distortion which may obstruct the winch rope, • Examine the winch drum for wear, distortion, and cracks, as far as

accessible, • Examine brake bands and drums and check for wear, • Ensure brake bands and drums are clean and free from

contamination, • Where fitted, examine the automatic brake and check springs, link

arms, and pins, • Examine exposed parts of the piston rod and check for corrosion, • With power disconnected ensure that all operating levers return to

neutral when released, • Ensure directional markings are in place and clearly visible, • Check oil level, • Ensure the correct wire rope is fitted and is wound in the correct

direction, • Do not overwind the rope on or off the drum, • Examine winch base and check for cracked welds, cracks around bolt

holes, distortion or impact damage, • Check that the power supply is adequate for that particular model of

winch, • Engage the power supply and function test the winch, • Visually examine the winch wire rope and check for wear, corrosion,

crushed or broken wires.

8.17.4.2 Periodic Inspection 8.17.4.2.1 General periodic inspection

The winch assembly shall be inspected regularly in accordance with the manufacturer’s recommendations and consistent with the requirements of the computerized maintenance management system or equivalent system.

8.17.4.2.2 Winch frame and fittings

When conducting inspection of the winch frame and associated fittings, special attention should be given, but not limited to, the following: • Winch frame is corroded, damaged or distorted, • Rope drum flanges are chipped or cracked, • Rope anchorage is damaged, • Ratchet / pawl is damaged, worn, or corroded, • Brake is worn or slipping, • Gears are worn, damaged, or not positively locating, • Loose or missing bolts, keys, or fixtures and supports, • Colour coding, if applicable, is not current and markings are illegible.



8.17.4.2.3 Winch wire rope

When conducting inspection of the winch wire rope, special attention should be given, but not limited to, the following: • An incorrect wire rope is fitted, i.e. diameter, type, • The wire rope is kinked, worn, corroded or has broken wires, • The wire rope termination is damaged, cracked or stretched, • The wire rope is fitted incorrectly.

8.17.4.3 Operation and Maintenance 8.17.4.3.1 General

When operating the winch assembly, be vigilant for load slippage, excessive effort required in the operation of the brake, or that the wire rope does not spool evenly. Any indication of problems in these areas should be brought to the attention of the Operations Supervisor. When conducting maintenance to the winch or any assembly components, ensure that the procedure and replacement parts used are governed by the manufacturer’s recommendations.



8.18 Fixed Lifting Equipment 8.18.1 Introduction

This section describes the PCSB requirements related to the selection, maintenance, and inspection of fixed lifting equipment. For the purpose of this section, fixed lifting equipment has been divided into two categories: • Runway beams / monorails, • Fabricated Padeyes / lifting points.

8.18.2 Runway Beams and Monorails 8.18.2.1 General inspection

Regular inspection of the runway beam or monorail should be carried out and the inspection should consider, but not be limited to, the items in the following list. Bring any defects to the attention of the Operations Supervisor/Platform Superintendent. • Any structural defects, damage, distortion, corrosion, or cracked

welds, • Loose or missing bolts, • Damaged or missing end stops, • Tracks not level or running surface uneven, • Illegible markings, i.e. identification number, SWL, etc.

8.18.2.2 General maintenance

General maintenance shall be in accordance with the maintenance management system or equivalent system requirements. In addition, bolts, fixtures and supports should be checked to ensure they are tight and, if necessary, re-torque. The running surface of the track should be kept smooth, clean and free of debris and obstruction and end stops must be in place, correctly set, and secure.

8.18.2.3 General operation

General operation practices should include, but not be limited to, the following considerations: • Check the runway beam before use - do not use defective beams, • Ensure the runway beam is clearly identified and marked with the Safe

Working Load (SWL), • Ensure the SWL is legible from the work floor, • Ensure the runway beam has positive end stops, which engage onto

the tread, not the flange of beam trolley wheels, • Do not side load the runway beam, • Do not let the trolley crash into the travel stops, as the load will swing,

causing an increase of the resultant loads on the runway structure, • In the case of runway beams fitted with more than one lifting machine,

take care to avoid collision or that any one span of the runway becomes overloaded due to the proximity of the lifting machines.



8.19 Fabricated Padeyes and Lifting Points 8.19.1 General inspection

Regular inspection of fabricated padeyes and lifting points should be carried out and the inspection should consider, but not be limited to, the items in the following list. Bring any defects to the attention of the Operations Supervisor/Platform Superintendent. • Damage (chip, bend, etc.), • Distortion, • Corrosion, • Cracked welds, • Elongated / stretched bores, • Illegible markings (Identification, SWL, etc.)

8.19.2 General maintenance

Maintenance requirements are minimal. Ensure that corrosion damage is prevented. Lifting support steelwork such as runway beams and fabricated padeyes, with no moving parts can be inspected annually, as long as: • They are not used for supporting personnel, • Due to infrequent to the extent that wear is not an adverse factor, • They are adequately coated / protected so that corrosion is not an

adverse factor. • Carry out annual NDT Inspection of welds.

8.19.3 General operation

General operation practices should include, but not be limited to, the following considerations: • Check the padeye before use - do not use defective padeyes, • Ensure the padeye is clearly identified and marked with the SWL, • Always use the correct size of shackle to avoid high stress due to

point loading, • Ensure the load is applied "in-line" only. Do not apply side loads. Note: See figure on next page



8.19.4 Cheek plates

The profile of the padeye should be smooth, free from any flame cutting marks, and the hole should be line bored after the fitting of cheek plates.

Cheek plates

In-line loading of the padeye is acceptable.

Side loading of the padeye is not acceptable.



Section 9 LEMS-09 Lifeboat Davits & Winches 9.1 Survival Craft Launching Appliances 9.1.1 Introduction

This section describes the PCSB requirements related to the testing and inspection of marine lifesaving appliance launching devices.

9.1.2 References

Reference is made to: International Maritime Organization, Safety of Life at Sea (SOLAS)

9.1.3 Testing and Inspection 9.1.3.1 General

Launching appliances for survival craft are to be tested and inspected periodically in accordance with manufacturer’s recommendations and applicable local and international statutory and regulatory requirements. Statutory minimum performance requirements are set forth in SOLAS, although it must be understood that the marine facility on which the device to be tested and inspected is located may not be subject to the requirements of those references

9.1.3.2 Definitions

The following definitions apply to this chapter: • Launching appliance - a means of transferring a survival craft or

rescue boat from its stowed position safely to the water. • Rescue boat - a boat designed to rescue persons in distress and

marshal survival craft. • Survival craft - a craft capable of sustaining the lives of persons from

the time of abandoning the vessel or marine platform; survival craft include inflatable life rafts, lifeboats, survival capsules, etc.



9.1.3.3 Guidelines

Inspection and testing of launching appliances should include, but not necessarily be limited to, the following: • Survival craft launching appliances shall be operationally load tested

at 1.1 times the total mass of the survival craft when loaded with its full complement of personnel and equipment; such test shall be conducted once every four years,

• The loading of the survival craft shall be via pellet bags, weights, or waterbags as available and suitable. The load should be evenly distributed and simulate, as near as is practicable, an actual load of personnel while taking into consideration the possibility of load shift and resultant damage to the survival craft in the process of the test,

• The fully laden survival craft should then be lowered away until the maximum lowering speed is reached, at which time the brakes should be suddenly applied and tested for effectiveness,

• A thorough visual examination of the heavily stressed parts of the davit and winch structures should be conducted, including welded areas on the deck,

• Depending upon the results of the thorough visual examination, additional non-destructive testing, such as magnetic particle or dye penetrant, may be carried out at the discretion of the examiner or inspector.

NOTE: With the exception of davit launched rescue boats, the winch is

designed, in accordance with SOLAS requirements, to hoist the survival craft with the handling crew only and not the full rated load capacity.

9.1.4 Maintenance and Inspection 9.1.4.1 Introduction

This section describes the recommended maintenance and inspection to be conducted on launching appliances.

9.1.4.2 Weekly maintenance and inspection

Weekly maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following:

• Inspect the wire rope (fall wire) for damage such as kinks, displaced or

broken wires, bird caging, etc., • Inspect the wire terminations for corrosion or damage, • Check the condition of the winch motor, • Check the condition and operation of the limit switches and lever

arms, • Check the adjustment of the brake and release linkage, • Check the handcrank ratchet for corrosion and proper storage, • Test the full launch system by gravity lowering and powered retrieval.



9.1.4.3 Monthly maintenance and inspection

Monthly maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following: • Conduct the checks described in the weekly inspection, • Lubricate the pushbutton of the motor starter with penetrating oil or

other suitable lubricant, • Lubricate the lever arms with penetrating oil or other suitable lubricant, • Check the oil level of the pressure reducer (or in-line lubricator if

applicable) and fill as necessary with non-detergent oil, • Check the oil level of the over-running clutch and fill as necessary with

oil for winches with heavy-duty clutch, • Lubricate the handcrank ratchet head with low temperature aircraft

instrument grease. 9.1.4.3 3 Monthly Maintenance and Inspection

Quarterly maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following: • Conduct the checks described in the monthly inspection, • Check the structure bolts, welds, attachments, and movable drums,

sheaves, etc. for corrosion and general condition; lubricate with low temperature aircraft instrument grease,

• Lubricate the brake release linkage with low temperature aircraft instrument grease,

• Lubricate the open gear and pinion with open gear lubricant.

9.1.4.5 6 Monthly Maintenance and Inspection

Semi-annual maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following: • Conduct the checks described in the quarterly inspection, • Lubricate the entire length of the winch wire rope (fall wire), • Lubricate the seals (O-rings) of the limit switch housing with

silicone-based lubricant.

9.1.4.6 Yearly Maintenance and Inspection

Annual maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following: • Conduct the checks described in the semi-annual inspection, • Inspect the brake mechanism for wear, • Lubricate the bearings with low temperature aircraft instrument

grease, • Change the oil in the over-running clutch and lubricate with grease.



9.1.4.7 4 Yearly Maintenance and Inspection

Quadrennial maintenance and inspection activities on survival craft launching appliances should include, but not necessarily be limited to, the following: Replace the wire rope (fall wire) assembly with a new and properly certified assembly.

9.1.4.8 Winch overhaul

Over-running clutches should be replaced on a ten-year basis in conjunction with the winch overhauls. Badly worn or corroded pinions or spur gears, or if lift is noted in the drum bearings, are an indication that winch overhaul is required.



Section 10 LEMS-10 Operation & Maintenance 10.1 Introduction

This section describes the PCSB requirement related to the selection, inspection, maintenance and operation of the following: • Offshore pedestal cranes. • Mobile Cranes • Overhead Cranes • Forklifts

10.2 Standards

Only equipment conforming to recognized standards, practices and specifications should be utilized for PCSB facility lifting operations. The following API & ASME standards, practices and specifications apply to the design, construction, installation, operation, inspection and maintenance of lifting equipment covered in this chapter:

• API Recommended Practice 9B “Recommended Practice in

Application, Care, and Use of Wire Rope for Oilfield Service, • API-9A Specification for Wire Rope, • API Specification 2C, Specification For Offshore Cranes, • API Recommended Practice 2D, Operation and Maintenance of

Offshore Cranes, • ASME B30.5 – Onshore Mobile Cranes, • ASME B30.17 – Overhead & Gantry Cranes, • ASME B56.10 – Forklifts.

NOTE: No lifting equipment shall be modified, in any manner, without

the input, evaluation, and endorsement of the crane or lifting equipment manufacturer or a qualified engineer. Approved design modifications that change the capacity rating require testing according to applicable design standards and regulatory requirements.

10.3 Offshore Pedestal Crane Mandatory Equipment & Safety Devices Equipment Minimum Standards Each pedestal crane both rental and fixed at a PCSB offshore facility must be equipped with the following mandatory devices and equipment, as per API 2C & API RP 2D.



10.3.1 Wire Rope

Wire ropes used shall: • Be of a construction specified by the Manufacturer and or Crane &

Lifting Contractor, • Wire rope terminations shall not reduce the wire rope strength to

below 80% of the wire rope nominal breaking load, • When handling personnel, a design factor (of load hoist wire rope) of

not less than 10, as required by API Specification 2C, Specification of Offshore Crane.

10.3.2 Sheaves

Sheaves shall be characterized as follows: • Sheave pitch diameter (PD) to nominal wire rope diameter (R) ratio

(PD/R) shall not be less than 18, (Figure 3 below) • Sheave groove contour shall be smooth and free from defects

injurious to the wire rope, • Sheave groove angle shall taper outwardly and shall not be less than

a 30° included angle, • Groove flange corners shall be rounded, • Sheave bearings shall be individually lubricated through a separate

passage, • All sheaves, including running blocks, shall be provided with guards or

other suitable devices to prevent the rope from coming out of the sheave groove.



10.3.3 Load Block Assemblies

Load block assemblies shall be characterized as follows: • The weight of the hook block shall be sufficient for the boom length

and parts of line specified to prevent slack wire rope when the main hoist drum is unwinding at maximum speed,

• No material shall be used to provide additional hook block weight, • Hook material shall be alloy steel and produced as a forging or

casting, • Hooks shall be equipped with a latch to retain loose lifting gear under

non-lifting conditions, • The latch shall be lockable if the hook is to be used for transporting

personnel, • The latch is not intended to support the lifted load, • The hook block shall be permanently marked with the rated load,

service temperature and assembly weight.

10.3.4 Boom Hoist and Load Hoist Mechanisms

Boom and load hoist assemblies shall be characterized as follows: • Boom and load hoists shall be approved by the hoist manufacturer for

personnel handling and shall be so indicated on their nameplate, • When power operated hoist brakes have no continuous mechanical

linkage between the actuator and the brake, a means shall be provided to set the brake to prevent the load from falling in the event of loss of actuating power,

• Brakes shall be provided to hold the drum from rotating in the lowering direction and shall be capable of holding the rated load indefinitely without attention from the operator,

• Brakes shall be automatically applied upon return of the control lever to its neutral position,

• Brakes, which are applied on stopped hoist drums, shall have sufficient impact capacity to hold 1.5 times the rated torque of the hoist,

• Boom or load lowering shall be done only by engagement to the power train,

• Free fall lowering of the boom or load shall not be permitted, • Hoist drums shall have sufficient rope capacity with recommended

rope sizes to operate within the range of boom lengths, operating radii, and vertical lifts as agreed to between the manufacturer and the purchaser (see Crane Manual),

• No less than five wraps of the wire rope shall remain on the drum in any operating condition,

• The drum end of the wire rope shall be anchored to the drum by an arrangement provided by the crane manufacturer (see manufacturer’s Crane Manual),

• All hoists shall be equipped with means to check lubricant and cooling levels. This means shall be readily accessible with wire rope in place and shall not require the use of special tools. Maximum and minimum levels shall be clearly marked,



• The boom hoist mechanism shall be capable of elevating the boom

from a minimum boom angle of 0º degrees to the maximum recommended boom angle or upon purchasers request, a lattice boom from a minimum angle of 10° degrees below horizontal to the maximum recommended boom angle,

• The boom hoist mechanism shall be capable of elevating and controlling the boom and design load within recommended minimum and maximum boom angles,

• The boom hoist mechanism shall be capable of supporting the boom and 110% of design load within recommended minimum and maximum boom angles,

• A hydraulic cylinder or cylinders may be utilized to control the elevation of the boom as follows:

The cylinder mechanism shall be capable of elevating the boom from a minimum of 0° to the maximum recommended boom angle,

The boom cylinder shall be capable of elevating and controlling the design load within recommended minimum and maximum boom angles,

The boom cylinder shall be capable of supporting the boom and 110% of design load within recommended minimum and maximum boom angles,

A positive holding device, (such as internally mounted check valves) shall be provided for boom support regardless of the type of drive,

On rope boom support machines, a ratchet and pawl or other positive holding device (such as integrally mounted check valves) shall be provided to prevent uncontrolled lowering of the boom.

10.3.5 Telescoping Boom Mechanisms

Telescoping boom mechanisms shall be characterized as follows: • A telescoping boom consists of a base boom from which one or more

sections are telescoped for additional length. Extension and retraction may be accomplished through hydraulic, mechanical, or other means,

• The powered retract function shall be capable of controlling design load and capable of supporting 110% of design load within recommended minimum and maximum boom angles,

• The powered extend function is not required to extend under load unless specified by the manufacturer,

• A holding device (such as check valves) shall be provided with telescoping cylinders to prevent uncontrolled movement of the cylinder.



10.3.6 Swing Mechanisms

Swing mechanisms shall be characterized as follows: • The swing mechanism, which is the means to rotate the upper

structure of the machine, shall be capable of smooth starts and stops with controllable rates of acceleration and deceleration,

• A brake, with holding power in both directions, shall be provided to restrain movement of the upper structure but not to retard the rotation motion of the upper structure during operation shall be provided; this brake shall be controllable by the operator, at his station and shall be capable of remaining in the engaged position without the attention of the operator,

• If a swing brake is of the automatic type, return of the swing control lever to neutral, shall not engage the brake in a manner to abruptly arrest the swing motion; an automatic swing brake that is incapable of controlled deceleration shall not be used,

• A dynamic friction brake to stop, hold, or retard the rotation motion of the upper structure may be provided and, when provided, it shall be controllable by the operator at his station,

• The swing mechanism shall be designed with sufficient strength and capacity to rotate the upper structure for all rated load, radii, and boom lengths. In the absence of information from the purchaser, the swing mechanism shall be designed to rotate the superstructure and rated load with a 1/2-degree tilt and a 30-mile per hour (48 kilometre per hour) wind applied to the superstructure, boom and an equivalent rated load area.

10.3.7 Swing Locks

A swing lock, a mechanical device (not dependant on friction) for positively locking the superstructure in one or more fixed positions, may be provided. When provided, it shall be constructed to: • Withstand maximum swing torque developed by the swing

mechanism, • Prevent accidental engagement or disengagement, • Be controllable by the operator at his station.

10.3.8 Prime Movers

Prime movers shall be characterized as follows: • Gasoline engines are not permitted as prime movers, • Pneumatic prime movers or auxiliary systems, which use flammable

gas as the fluid medium, are not permitted, unless a risk assessment has been completed and appropriate management approval obtained.



10.3.9 Exhaust Systems

Exhaust systems shall be characterized as follows: • Engine exhausts shall be equipped with a spark arresting type

silencer, unless a risk assessment has been completed and the appropriate management approval obtained.

• Exhaust gases shall be piped to the outside of the engine enclosure and discharged in a direction away from the operator,

• All exhaust systems shall be guarded in areas where contact by personnel in the performance of their normal duties is possible.

10.3.10 Fuel Tanks

Fuel tanks shall be characterized as follows: • Fuel tanks shall be equipped with filler necks and caps designed to

prevent fuel contamination from external sources; removable caps, where fitted, shall be securely tethered to the filler,

• Drains shall be provided on all fuel tanks. Drains shall be located to drain the tank below the level of the fuel pick-up.

10.3.11 Hazardous Area Classification

Prime movers installed in areas classified as hazardous by API RP 500B "Classification of Areas for Electrical Installations at Drilling and Production Facilities" shall meet the Recommended Practice as it pertains to elimination of ignition sources in classified areas.

10.3.12 Overspeed Shutdown

Diesel engines shall be equipped with a device to shut off intake air in the event of a runaway unless another shutdown mechanism was provided on initial installation at the request of the platform owner.



10.3.14 Controls

Control devices and associated support equipment shall be characterized as follows: • All controls used during the normal crane operating cycle shall be

located within easy reach of the operator while at the operator's station,

• Control levers for boom hoist, load hoist, swing and boom telescope (when applicable) shall return automatically to their centre (neutral) positions on release,

• Control operations and functions shall be clearly marked and easily visible from the operator station; this can be done by marking each control or by a control arrangement diagram,

• Provisions shall be made for emergency stop of the crane operations by the operator at his control station,

• Foot operated pedals, where provided, shall be constructed so the operator's feet will not readily slip off,

• Controls for normally operating prime movers mounted on the crane superstructure shall be within easy reach of the operator and shall include means to start/stop, control speed of internal combustion engines, stop prime mover under emergency conditions and shift selective transmissions,

• All cranes with a direct mechanical drive to any crane function shall be provided with a clutch or other effective means for disengaging power. The clutch control shall be within easy reach from the operator's station.

10.3.15 Cabs and Enclosures

Insofar as practical, all cabs and enclosures shall be constructed to protect the upper structure machinery, brakes, clutches, and the operator's station from the weather. Cranes, which do not have cabs or enclosures to protect the operator, superstructure machinery, brakes, and clutches, shall be adequately protected from the corrosive influence of the offshore environment.

10.3.16 Windows

All windows shall be of safety glass or equivalent and shall be provided in the front and both sides of the operator's cab for visibility forward and to either side. Visibility forward shall include a vertical range adequate to cover the boom point and load at all times. The front window may have a section that can be readily removed and held open if desired. If the section is removable, storage space shall be provided. If the section is of the type held in the open position, it shall be secured to prevent inadvertent closure. The lower portion of the front window shall have a grating or other means to prevent the operator falling through. If the cab is equipped with an overhead window, a grating or other protection should be placed over the window to prevent debris from falling on the operator.



10.3.17 Window Wipers and Washers

If specified by the purchaser, sufficient window wipers and washers shall be provided to ensure a clear view of the boom tip and load at all times.

10.3.18 Doors

All cab or enclosure doors, whether of sliding or swinging type, shall be adequately restrained from inadvertent opening or closing while the machine is in operation. The door adjacent to the operator, if of the sliding type, shall slide rearward to open and, if the swinging type, shall open outward. A clear passageway shall be provided to the exit door nearest the operator’s station.

10.3.19 Cab Access

Suitable hand holds or steps shall be provided for access to and exit from the operator's cab or enclosure.

10.3.20 Platforms and Walkways

Principle walking surfaces shall be an anti-skid type. Outside platforms, if furnished, shall be provided with guardrails. All walkways and platforms shall have a minimum width of 30 inches (760 mm) unless otherwise specified at the time the machine was installed on the platform.

10.3.21 Rigging Access

Rigging access shall be characterized as follows: • Where necessary for rigging or service requirements, a ladder or

steps shall be provided to give access, • Where necessary, areas of cab roof or enclosure shall be capable of

supporting without permanent deformation, the weight of a 200-pound (90kg) person.

10.3.22 Boom equipment

Boom equipment shall be provided as follows: • A boom hoist limiter or shutoff shall be provided to automatically stop

the boom hoist when the boom reaches a predetermined high angle and a low angle limiter or shutoff is also recommended,

• Boom stops shall be provided to prevent the boom falling backwards in a high wind or sudden release of the load e.g. a fixed or telescoping bumper, a shock absorbing bumper or hydraulic boom elevation cylinder,

• A boom angle or load radius indicator readable from the operator's station shall be provided. A boom length indicator readable from the operator's station shall be provided for telescoping booms, unless the load rating is independent of the load radius,

• A load moment or a load-indicating device, where fitted, must be operable.



10.3.23 Guards for moving parts

Exposed parts such as gears, chains, chain sprockets or rotating parts, which may constitute a hazard under normal operating conditions, shall be guarded. Guards shall be securely fastened and shall be capable of supporting without permanent deformation, the weight of a 200-pound (90kg) person unless the guard is located where it is impossible to step on it. If a guard is impractical, an appropriate warning sign must be posted.

10.3.24 Clutch and brake protection

All friction brakes and clutches shall be provided with rain guards. Pins, shafts, and bolts in clutch and brake linkages shall be protected against corrosion.

10.3.25 Lubrication points and fluid fills

Lubricating points on all parts shall be accessible without the necessity for removing guards or other parts. Fluid fill points shall be located in areas that are easily accessible and will not collect fluid spills. Refer to the Lubrication Charts in the manufacturer’s Crane Manual.

10.3.26 Hydraulic and pneumatic line protection

Exposed lines subject to damage shall be protected as far as practical.

10.3.27 Anti-two block

Means shall be provided to protect hoist ropes, structural components and machinery from damage which may occur when two sheave groups (e.g. load block and boom head) come into contact as the hoist cable is drawn in. A control override device or proximity warning device may be used. Stalling of the hoist drum is acceptable where damage or loss of control would not result.

10.3.28 Personnel Emergency load lowering

Unless otherwise specified by the purchaser, at least one hoist drum shall be provided with a means of lowering in the event of a power failure or control system failure. This means shall provide controlled lowering and stopping of the drum under all load conditions. The controls shall be arranged in a manner that will prevent inadvertent engagement. An alternate power source independent of the crane may be used. An instruction plate giving detailed instructions shall be provided at the operator's station.



10.3.29 Marking

Cranes that are installed on offshore drilling units and fixed production platforms where jurisdictional authority requires nameplate confirmation of construction to API Specification 2C shall have a permanent nameplate of stainless steel or other metallic material of equal corrosion resistance in a marine environment affixed to a conspicuous location protected from damage and disfigurement. The nameplate shall be imprinted with the required information in 1/8" (4 mm) raised or stamped lettering.

10.3.30 Use of Environmentally Sensitive Materials

Paint containing lead or chromate shall not be used on a crane or any of its components. Asbestos shall not be used on a crane or any of its components.

10.3.31 Safety Devices

Bypassing, disabling or defeat of equipment safety devices Cranes may be equipped with a variety of mechanical or electronic devices to aid the operator, provide information to the operator, or override the operator. Safety devices must never be routinely bypassed, defeated, or disabled. Examples of such safety devices are: • Anti two-block indicating and shutdown devices, which prevent the

load block or overhaul ball from coming to near the boom or jib tip, • Over booming devices, which prevent the boom from reaching a

predetermined maximum angle, • Load moment or rated capacity alarm and shutdown devices, which

warn or shutdown crane operations when overload situations are sensed.

Safety devices can only be bypassed for crane inspection, maintenance, and testing purposes. Authorization for bypass at any other time MUST: • Be driven by extreme circumstances, • Be supported by a risk-based analysis, • Be supported by a Permit, JHA and approved work procedures, • Be carried out under the supervision of an experienced crane

engineer.

10.3.32 Requirements for bypassing authorization

Bypass authorization for offshore pedestal cranes shall require: • The concurrence of a crane subject matter expert and the crane

custodian, • The endorsement of the Platform Superintendent/Operations

Supervisor, • Issue of a Permit to Work with associated JHA.



10.3.33 Documentation

General Requirements

All lifts, inspections, testing and maintenance for offshore pedestal cranes shall be documented according to the following minimum requirements: • Pre-use crane checks by certified crane operators should be formally

documented, • All pedestal crane operations shall be documented in the daily crane

operations log, • The crane supplier, crane contractor or crane custodian shall be

responsible to provide and determine the location where the log shall be located; the log is normally located in the cab of pedestal cranes,

• The crane operator shall update the daily crane operations log, • Completed crane operations logbooks shall be retained at the location

for a minimum of two years, • Pre-use inspections of pedestal cranes shall be documented and

retained for a minimum of two years at the location, • Periodic inspections in accordance with API specifications must be

documented to substantiate compliance. The Crane and Lifting Contractor shall document the inspection and testing reports. These records shall be retained and made part of the permanent crane record by the crane custodian,

• All programmed maintenance and corrective maintenance work must be documented to the requirements of PCSB and or Crane & Lifting Contractors endorsed system,

• All critical lifting plans shall be retained as part of work order history and reporting requirements.

10.3.34 Crane Manual

Fixed marine installation requirements

A Crane Manual shall be provided for all cranes at fixed marine installations. The manual shall include but not be limited to full information concerning the following: • Design standards and operation, • Manufacturer’s maintenance, inspection, and testing information on

the slew/swing circle assembly, • All limitations during normal and emergency operations with respect

to: safe working load, safe working moment, maximum wind, design temperatures, braking systems,

• All safety devices, • Diagrams for electrical, hydraulic, and pneumatic systems and

equipment, • Materials used in construction, welding procedures, and extent of non-

destructive testing, • Guidance on maintenance and periodic inspection.



10.3.35 Mobile marine installation requirements

A Crane Manual shall be provided for all cranes at mobile marine installations. The manual shall include all items required for the Fixed Installation Crane Manual, in addition to full information concerning: • All limitations during normal and emergency operations with respect to

maximum heel and trim.

10.3.36 Operations with service vessels

In addition to the above requirements, Crane Manuals for fixed and mobile installations that are used for the loading or unloading of offshore supply or other service vessels shall be furnished with: • Rating tables or curves that take into consideration the dynamics

associated with the vessel’s motion.

10.3.37 Selection General

Offshore pedestal cranes are designed and permanently installed to serve the lifting needs of their locations. In this sense, there is no selection process comparable to that of mobile cranes. The crane operator or lift planner makes a yes/no decision to select these cranes based on the following: • Crane suitability for the lift, • The radius at which the load must be handled based on the position of

the crane in relation to load pick up and drop points, • Gross weight of the load, • Lift classification and lift plan requirements, • Load limitations of structure it is being mounted on to.

10.3.38 Manufacturer Responsibilities

In the selection, specification, manufacture and providing of Offshore Pedestal Cranes, both the Purchaser and the Manufacture bear certain responsibilities under API 2C. These responsibilities on the part of the Manufacturer are summarized in the following: • Prepare a list of critical components for each crane, • Maintain all testing and inspection records, • Provide load and information charts, • Provide a list of all critical components and a certification that these

components meet the API 2C requirements for material, traceability, welding (as applicable), and non-destructive examination requirements,

• Provide failure mode assessments for unintended overloads, • Provide an Operations, Parts, and Maintenance Manual, • Provide Kingpost or pedestal mounting dimensions at the

crane/platform interface, • Provide overturning moment with corresponding axial and radial load

at the crane/platform interface, • Provide maximum axial load with corresponding overturning moment

and radial load at the crane/platform interface, • Allow access by the Purchaser to manufacturer design calculations,

drawings, and other pertinent information necessary to assure compliance with this specification,



• Provide certification that the crane furnished to this specification

meets the material and dimensional specifications used in the calculations,

• Certify that a prototype, design, or major structural revision to a design has been tested in accordance with the Resistance Type Strain Gauge Test or the Heavy Lift Load Test as described in the Specification,

• Conduct an operational test as agreed to by the Purchaser and the Manufacturer. Testing may include, but not necessarily be limited to, the following:

Auxiliary and main line load testing at various radii, Speed test for main line, boom luff, and swing, Swing and free swing tests, Overload test (1.33 times the rated capacity) or otherwise

specified by the Purchaser, Anti-two block tests\Upper and lower boom kick out tests, Engine functional tests, and Emergency lowering,

• Provide Inspection, Maintenance, and Replacement procedures for all wire rope used in the crane,

• Provide installation procedures for wire rope end terminations, • Provide, through the Hoist manufacturer, a mounting procedure that

prevents excessive distortion of the hoist base as it is attached to the mounting surface,

• Provide, if specified by the Purchaser, a device to restrain the movement of the upperstructure of an out of service crane, in one or more fixed positions,

• Provide a test procedure that illustrates the test methods to be performed on the finished cane prior to shipping from the manufacturer’s facility,

• Furnish, with the proposal, the minimum braking strength, parts if line used, rope diameter, design factors, rope construction, length, end connections, etc.,

• Describe the inspection and testing procedure for slew ring bolts and submit to the Purchaser for comment and approval,

• Submit power calculations, along with the quotation, for the Purchaser’s review,

• Provide sound level test results to the Purchaser, • Confirm that the location of the boom rest is acceptable and poses no

excessive stresses on the cranes, • Prior to the start of manufacture, provide a list of methods of non-

destructive examination procedures and acceptability standards of all critical crane components,

• Ensure that the non-destructive test records for all components produced by suppliers other than the manufacturer are provided as part of the final documentation records,

• Forward a full set of inspection and test records to PCSB commensurate with the delivery of the ordered crane,

• Create a “ship loose” item list and package all ship loose items in clearly marked crates to prevent loss or damage to the items during shipment or idle time prior to final installation at the destination,



• After the purchase order has been placed and prior to delivery of the

crane, furnish a complete set of general arrangement drawings showing the recommended procedure for installation. The drawings shall indicate the location and size of padeyes and the weight and center of gravity of each individual piece of equipment which will be shipped and unassembled,

• After the purchase order has been placed and prior to delivery of the crane, furnish a description of the field replaceable lacing guard,

• Provide a complete set of the following data after final testing: A complete pictorial of all replacement parts on the crane with

reference numbers. The replaceable parts shall also have a complete generic description describing the part,

A listing of recommended spare parts for twenty-four months of operation,

Expected lead time for supply of components, A compete list of all hose sections showing size, pressure rating,

length and end connections, Diagram of the hydraulic system for the crane, A list of the wire rope for each hoist and pendent lines showing

size, type, length, and rating. Breaking strength certificates are required for each wire rope,

A final copy of the Crane Data Sheet, Identification of all lubricants, hydraulic oil, and coolants. Crane

manufacturer shall provide an PCSB product equivalent list for all fluids and lubricants,

• The engine manufacturer’s operation and maintenance manual, • A general operation and maintenance manual for the crane itself, • A copy of the crane load chart shall be included in the data exactly as

it appears on the crane. • OEM part numbers shall be given for components not manufactured

by the crane manufacturer. This shall include a complete spare parts listing for all components such as winches, pumps, motors, etc.,

• All procedures for slew ring changeouts as described in API 2C. Documentation shall include full details, part numbers, etc. of equipment required to carry out the work,

• Inspection and testing procedures for slew ring bolts as described in API 2C,

• Procedures for periodic load testing of the crane, • All supporting documentation for “Critical Components” as per

Appendix A of API 2C, • Provide details of original clearance figures and allowable wear limits

for all boom connection points including pivot point and boom section joints. Included shall be all data required to determine the retirement of a boom and/or its sections,

• Provide inspection/replacement schedule for slew ring bearing (if fitted), allowable wear limits, and procedures for measuring,

• Provide a detailed recommended Time-Life for all hydraulic components and winch components,

• Furnish reproducible drawings that are “First Generation” quality. • Provide standards warranty certificates. The service life warranty shall

include the standard period of operation in addition to the time the crane is in operation during the fabrication and installation of the platform.



10.3.39 Purchaser (PCSB) Responsibilities

In the selection, specification, manufacture and providing of Offshore Pedestal Cranes, both the Purchaser and the Manufacture bear certain responsibilities under API 2C. These responsibilities on the part of the Purchaser (PCSB) are summarized as follows: • Supply the velocity Vc used in equation 4.1 (see API 2C) to calculate

the dynamic coefficient Cv, • Also specify (not required, but recommended) the onboard lift Cv

instead of using Table (3) provided in API 2C, • Also specify (not required, but recommended) the crane vessel static

inclinations and the crane dynamic horizontal accelerations instead of using Table (4) provided in API 2C,

• Supply specific data for horizontal loadings, otherwise to be determined by API 2C,

• Specify wind speeds for in service and out of service conditions, otherwise to be determined by API 2C,

• Specify simultaneous operations requirements (hoist, luff, swing), which will significantly affect plant sizing requirements,

• Specify the classification of the area in which the crane is to be installed,

• Specify if sound levels need not apply, • Specify if diesel engine(s) need not be equipped with a device to shut

down engine air intake in the event of a runaway, • Specify if at least one hoist drum need not be provided a means of

lowering personnel in the event of power failure or control system failure,

• Specify the location of the boom rest, and • Specify the lowest anticipated (design) service temperature.

10.3.40 Inspection

General Requirements

Offshore pedestal cranes must be inspected in accordance with API Recommended Practice 2D. Inspections may be conducted at more frequent intervals, as determined and guided by manufacturer recommendations, facility experience and severity of the working environment. The requirements in the following discussions are based on API Recommended Practice 2D and shall be applied to all offshore pedestal cranes used on PCSB facilities. NOTE: Although inspection procedures for offshore pedestal cranes are

divided into three general categories based upon their usage, PCSB policy is that all pedestal cranes on PCSB offshore facilities are subject to a "Heavy Usage" inspection program. These inspections are not to be confused with the routine Planned Preventative Maintenance (PPM's).



10.3.40.1 Crane Category and Inspection Types

Heavy Usage This inspection type applies to cranes that are used for 50 hours or more per month. These cranes will be subject to pre-use, monthly, quarterly, and annual inspections. Cranes assigned to this category usage do not need to be reviewed to determine the number of hours used each month. Initial Inspections Initial inspections apply to cranes that are new and are being placed into service and to cranes that are being permanently relocated. A qualified inspector will perform these inspections. Every initial inspection will include a proof load test consistent with the guidelines. Frequent (pre-use) inspection The pre-use inspection will be performed prior to the lifting operation, and then, as the certified operator deems necessary during the day for extended operations. A certified operator will perform this inspection and it will be applied to all cranes. Monthly inspection Monthly inspections are performed by a certified operator. 3 Monthly Inspection Quarterly inspections are performed by a qualified inspector. Yearly Inspection Annual inspections are performed by a qualified inspector. Records archive The crane custodian will keep and maintain a log of inspections and load tests with the inspector’s name and the date of the inspection. Records of such inspections and load tests, as well as records of repairs or modifications shall be kept readily available for a period of two years. Crane custodian will provide copies to each location.



10.3.41 Frequent (Pre-use) Inspections

General

Frequent or pre-use, inspections are performed by a certified operator and may include, but not be limited to, the following: • Check all fluid levels of the prime mover, • Check all safety devices, • Check control mechanisms including brakes and clutches for proper

operation, • Check boom hoist limit and anti-two block devices for proper function, • Visually check for hoist lubricant oil leakage. In hoists where a sight

glass is provided, also check the fluid level, • Visually check for leakage or damage in the air and non-mechanical

systems, • Boom hoist pawl, if applicable, • Helicopter warning lights, if applicable, • Crane hook latch, • Perform a walk round visual examination of the crane boom and

support structure to ensure that no damage exists, • Ensure the correct load-rating chart for the configuration in use is

visible to the operator at the primary control station, • Visually check wire rope for evident deterioration and damage, or

improper reeving, • Visually check for loose, missing, or corroded bolts, pins, keepers or

cotter pins, • Lubricate components and correct deficiencies as required based on

the results of these inspections.

10.3.42 Monthly Inspections

General

Monthly inspections are performed by a certified operator and may include, but not be limited to, the following: • Carry out the checks as described in the pre-use inspection, • Further check all control mechanisms for proper adjustment,

excessive wear of components and by contamination by foreign matter,

• Check electrical apparatus for proper function, • Lubricate components and correct deficiencies as required based on




10.3.43 3 Monthly Inspections

General

Quarterly inspections are performed by a qualified inspector and may include, but not be limited to, the following: • Carry out the checks as described in the monthly inspection, • Boom should be checked for bent chord members, missing or broken

lacing and cracked welds on critical members, • Boom section end connections should be inspected for cracked welds,

deformation and corrosion, • Check boom angle/radius indicators over full range for accuracy, • Sheaves should be inspected for wear, cracks, rope path alignment

and bearing condition, • Check prime mover for proper performance compliance with safety

requirements, • Check belts and chains for proper adjustment, • Visually check cranes hooks for deformation and discard if

deformations exceed those of manufacturer's recommendations, • Check lubricant levels in all hoists and slew/swing drives, including

those not fitted with sight glasses, • Lubricate components and correct deficiencies as required based on




10.3.44 Yearly Inspections

General

Annual inspections are performed by a qualified inspector and include, but not be limited to, the following: • Carry out the checks as described in the quarterly inspection, • Inspection of crane critical components. The annual inspection of critical components appropriate for an individual machine will differ, depending on the crane type and design of the individual components. A basic guideline for inspection of critical crane components should consider, but not be limited to, the following: • Hoist assemblies - The quality of the hoist lubricant is considered a

primary indicator of the mechanical integrity of the hoist. Brakes should be tested by stalling the drive.

• Foundation - Weldments in the crane pedestal and supporting deck structure should be visually examined for fracture, deformation and corrosion.

• Slew/swing circle assembly - The slew/swing circle assembly is the connecting component between the crane revolving superstructure and the pedestal. There are three main types of slew/swing circle assemblies typically used on pedestal cranes:

Hook and roller assemblies, King posts, Ball/roller bearing.

The inspection procedure for each varies significantly and must be tailored, not only to fit the type of slew/swing circle assembly but also for the physical and operational environment of each particular crane and platform. • Regardless of the type of slew/swing circle assembly, the objective of

any inspection is to determine and monitor wear, fatigue, corrosion and the overall operational condition. The crane and slew/swing circle assembly manufacturers are the best sources of information in developing the inspection program.

10.3.45 Critical Components

General

Critical components are those requiring particular attention from the operator and other inspections personnel. These components are subject to high stress and dynamic loading or are of such a nature that their failure or inoperability may lead to severe reduction of safety or operational reliability. There are three general categories of critical components: • Mechanical components, • Structural components, • Rigging components.



10.3.46 Mechanical components

Critical mechanical components include but are not limited to: • All linkage between the brake control element and the component to

be controlled, • Hoist and slewing/swing brake systems, • Drums, shafts, and gears of hoisting and slewing/swing systems, • Slewing/swing rings.

10.3.47 Structural components

Critical structural components include but are not limited to: • Boom chord members, • Boom section connection components, • Boom foot pins, • Boom jib section and connection components, • Primary load members of gantries, masts and A-frames, • Load transfer members of the superstructure including fasteners, • Pedestals and swing circle transition pieces, • Fasteners in critical load path of all critical components.

10.3.48 Rigging components

Critical rigging components include but are not limited to: • All running wire ropes in hoist systems, • All standing wire ropes in load restraint and support systems, • Hook block assembly, • Overhaul ball or weight assembly, • Wire rope dead-end connection devices, • Floating harness or bridle assemblies, • Wire line sheaves and sheave shafts.

10.3.49 Load Testing

When required as per API RP 2D Latest Edition: A crane load test is required under the following conditions: • New cranes being placed into service, • Cranes that are being permanently relocated, • After major repair or alteration of critical components. Note: There is no requirement to carry out an Annual Load Test

under these guidelines.



10.3.50 General guidelines

Load testing procedures shall incorporate the following minimum guidelines: • The designated qualified inspector must carefully choose the load

applied to the crane during the test, • Since the test loads are based on the crane-rating chart, the qualified

inspector must be familiar with the applicable load-rating chart. The load-rating chart will show the maximum capacity for each radius,

• Since it is obviously impossible to test all of the crane components at the same time, the qualified inspector should choose test loads that specifically stress the repaired or altered component,

• Since the crane's hoists and ropes will be used to impose the overload on the crane, the qualified inspector should choose a test load that is within the capacity of the hoists and wire ropes as normally rigged. The crane should not be rigged with extra parts of line to lift a greater test load at a closer radius. The test load can be imposed on the crane with a lesser load at a greater radius,

• The qualified inspector should be aware that line pull on some non-mechanical and electric hoists may be self-limiting. The load test requires only that these hoists, when self-limiting, lift at least 100% of rated load,

• It is the responsibility of the qualified inspector to select the load test procedures best suited for the requirements and conditions of each test,

• The crane shall be operated during the test in accordance with API Recommended Practice 2D,

• The crane shall be thoroughly inspected per "Annual Inspection" before and after the test,

• Test weights or dynamometer/load cell should be verified for accuracy by the qualified inspector,

• All lifts should be planned in advance taking into account the crane's physical location, the available space for staging and assembling the test loads and the hazardous areas to be avoided,

• Crane load indicators shall not be used to test cranes, but the readings should be recorded on each lift where load indicators are installed on the crane,

• Relief valves on hydraulic cranes should not be adjusted above manufacturer's recommended pressures and current-limiting devices on electric cranes should not be by-passed or adjusted to increase available hoist line pull. The test can be conducted with the highest load the hoist can lift as long as it is in excess of the static rated load,



10.3.51 Test load

The test load for all lifts shall be based on crane rating chart, wire rope strength, available hoist line pull and number of parts of line. The static test load and the test radius should be calculated to load the crane as follows:

Static Rated Load in Metric Tonnes at a Specific Radius

Test Loads in Excess of Static Rated Load at a Specific Radius

0 to 20 Metric Tonnes + 25% 20 Metric Tonnes to 50 Metric Tonnes + 5 Metric Tonnes 50 Metric Tonnes or more + 10% 10.3.52 Load application

There are two methods of applying the test load: • Suspended weight method, • Dynamometer method.

10.3.53 Suspended weight method

Guidelines for the Suspended weight test are as follows: • Select a suitable test load, • Assemble the load, • Lift the load, • Boom out to the desired radius, • With the load suspended, • Set the load hoist and boom hoist brakes, • Check for drum rotation. The test does not require that the test load be boomed or swung.

10.3.54 Dynamometer method

Guidelines for the Dynamometer test are as follows: • Determine the available dynamometer tie-down locations, • Measure and record the radius value, • Align the boom point with the tie-down, • Attach the dynamometer, • Verify that the load hoist line is vertical, • Pull with the load hoist until the desired test load is indicated on the

dynamometer, • Set the load hoist brake, • Check for drum rotation. • NOTE: Dynamometer locations (north, south, east, and west) and

radius values should be varied, if possible.



10.3.55 Test report

The load test report should include but not be limited to the following: • Equipment Tag Number and manufacturer’s serial number, • Description of crane under test, • Manufacturer of the crane, • Date of manufacture of the crane, • Make and model of safe load indicator, if applicable, • Date of last thorough inspection of the crane, • Auxiliary line rated capacity, test load and test radius, if applicable, • Main hoist line rated capacity, number of parts of line, test load and

test radius. • Name and signature of the testing engineer, • Name of the company carrying out the test.

10.3.56 Proof Load Testing for Personnel Handling

Proof load testing

With respect to PCSB cranes involved in personnel handling operations, PCSB recommendations are that: • Dynamic load testing (utilizing water weights or solid weights) is

conducted, which provides for the crane to be boomed in and out, hoisted and slewed however, it is also recognized that this method is not always practical due to the availability of equipment,

• A static proof load test is carried out every 3 years, which would fall into line with the stripdown inspection of personnel handling hoists.

10.3.57 Stripdown – Inspection

With respect to Stripdown Inspections for personnel handling cranes covered in this section: • Personnel handling hoists should undergo a "stripdown" inspection

onshore, • A "stripdown" inspection will include the hoist being completely

disassembled, cleaned, and inspected, and the replacement of all worn, cracked, corroded or distorted parts such as pins, bearings, shafts, gears, brake rotors, brake plates, drum and base,

• The stocking of replacement parts shall be regarded as essential to this procedure,

• The rebuilt hoist will be line pull tested to the rated load, • After inspection, rebuild, and testing, a new certificate for personnel

handling will be issued, • A personnel handling hoist register shall be kept so that each hoist

can be traced and the date of when the hoist was put into service is recorded and to which crane the hoist is fitted.

• During the "stripdown" inspection of personnel handling hoists, it is recommended that the hoist wire rope be changed out.



10.3.58 Maintenance

Programmed maintenance

A preventative maintenance program will be established by the Owner and or Crane & Lifting Contractor, taking into consideration crane type, frequency of usage, history of maintenance and manufacturer's recommendations. Written and dated maintenance records will be readily available for a period of two years.

10.3.59 Repairs and Replacements

If unsafe conditions are disclosed by the inspection requirements, the crane will be taken out of service or its operation restricted to eliminate the unsafe condition. In addition: • Repairs or replacements of critical components shall be made

promptly, • Written reports shall be maintained by the Crane Owner and the

Crane & Lifting Contractor, • All major replacement shall equal or exceed the original equipment

manufacturers recommended practices, • No welding repairs shall be made to critical components, such as

booms and slew/swing ring assemblies without specific repair procedures and recommendations from the Original Crane Manufacturer and or Crane & Lifting Contractor,

• Care should be taken while welding, to ensure that arcing does not occur across the bearings,

• Field welding shall not be performed on load hooks.

10.3.60 Lubrication

The crane or component manufacturer's recommendations as to points and frequency lubrication, maintenance of lubricant levels shall be maintained.

10.3.61 Records archive

The Crane Custodian will keep and maintain a log of all maintenance, repairs and modifications with the name of the inspector and the date of the inspection. Records of such maintenance, repairs, and modifications shall be kept readily available for a period of two years.

10.3.62 Operation 10.3.62.1 General

Operators, trainees, and riggers Requirements for crane operators, trainees, and riggers/banksmen are to be found in Section 11. Practices and Load Handling Hand signals Hand communications shall be consistent with standard convention, agreed upon in advance of the operation, and used by all personnel involved in the lifting operations. Standard API hand communications are depicted in the API Hand Signals.



Attachment 1 Crane Hand Signals



10.3.63 Operator practices

General practices that the operator is responsible for complying with include, but are not limited to: • A Lift Permit is required for any load greater than 8te, • The certified operator will be responsible for operations under his

direct control, • Whenever there is any doubt as to safety, the operator will have the

authority to stop and refuse to handle loads or continue operations as safety dictates,

• The operator will be aware of the operating characteristics of the crane,

• The operator will be familiar with the equipment and its proper care, • Before starting the crane the operator shall ensure that the pre-use

inspection has been carried out; all controls are in the off or neutral position and that all personnel are clear of the crane,

• When handling loads the operator will never start machine movement unless the load is within his range of vision or the appointed banksman/rigger has given the appropriate signal,

• The operator shall respond to only signals from the banksman/rigger, but shall obey an emergency stop signal at any time, no matter who gives the signal, and

• The operator shall never leave the crane before: landing any attached load, disengaging the master clutch, where applicable, setting all locking devices, putting controls in the off or neutral position, stopping the prime mover, assuring that no component of the crane will interfere with normal

helicopter flight operations.

10.3.64 Load handling

The responsibilities of the operator, with respect to load handling, include but are not limited to: • Before a load is attached, the operator must be aware of the weight of

the load to be lifted and be satisfied that the lifting gear being used is certified (i.e. colour coded), of sufficient capacity and is correctly attached and positioned, to prevent uneven lifting or slippage of the load,

• Prior to hoisting, ensure that the banksman/rigger has correctly positioned the hook over the centre of the lifting point; this should alleviate any "drift" in the load as it is lifted clear of the deck,

• When lifting from baskets or containers the lift shall not commence until personnel are clear of the immediate area of the lift,

• As the load is being lifted, the operator should monitor the safe load indicator for a possible overload situation developing,

• When moving loads across the deck, the operator should be aware of any other activities/obstructions within the crane radius arc and shall, whenever possible, avoid the movement of loads over the heads of other personnel,

• When possible, erect barriers around the lifting zone to stop personnel from entering the lifting area,



• When carrying out any "blind" lifts, monitor the safe load indicator for

any loss or increase in the weight of the load; this could indicate that the load has snagged,

• The operator should always keep the load within the specified radius of the crane,

• When hoisting loads off a moving supply vessel deck packed with cargo, the operator should be alert for snagging or wrongly manifested cargo weights,

• Where it is necessary to transfer personnel to or from a vessel, the crane operator must always have a clear view of the embarkation areas, load path and landing areas,

• All crane operations shall stop during helicopter landings, unless dispensation has been given to carry out special tasks,

• Always ensure that the aviation lights remain switched on when the boom is in the air and when A-frames or masts extend above the helideck.



Attachment 1 – Crane Operators Daily Check list

Daily Routine Check Platform: ______________________ Date: __________________________ Tag No: ________________________ Running Hours: _________________ Crane Operator: _________________ PRE-START UP CHECK Prior start up, check the following (If not applicable, enter N/A in Remark column). Activities Condition Remarks

1. Radiator water level

2. Engine oil level

3. Pump drive oil level

4. Hydraulic oil level

5. Diesel fuel level

6. Air start oil level

7. Engine for oil leak

CAUTION: Ensure the followings prior engine start up: All “BYPASS” switches are in normal position. Not bypassed. All controls are in the “OFF” or “NEUTRAL” position. All personnel are in the “CLEAR”. (A special permit along with a JHA are required if crane is to be operated in a bypass mode).

AAFFTTEERR EENNGGIINNEE SSTTAARRTT UUPP CCHHEECCKK

Activities Condition Remarks

1. Record engine RPM on idle

2. Check all lightings, beacon, buzzer and electrical; switches

3. Test swing brake and swing lock pawl

4. Test main hoist limit switch

5. Test fly hoist limit switch

6. Test boom hoist limit switch

7. Test swing limit switch operation



8. Check boom lock pawl actuator for operation when neutral

9. Test all brake systems on hoist drums are functional

10. Check load and boom angle indicator are functional

11. Check all gauges in cabin are operational

12. Visually inspect all hydraulic hoses and winch drums for leak

13. Ensure all motion controls return to neutral freely.

CRANE OPERATOR: _____________________________________ OPERATIONS SUPERVISOR: ______________________________



WWEEEEKKLLYY ((SSUUNNDDAAYY)) CCHHEECCKK LLIISSTT Platform: __________________________ Date (Sunday):______________________ Tag No: ___________________________ Running Hours: ____________________ Crane Operator: ____________________ Activities Condition Remarks

1. Complete all items in the Daily Checklist

2. Cooling fan belt for tightness

3. Condition of radiator for leaks

4. Ladders and walkways for security

5. Wire ropes for damage, broken wires, lubrication and spooling

6. Boom chord and lacing for damage

7. Sheaves for wear and damage

8. Loose or missing bolts, pins keepers and cotter pins

Additional Comments: CRANE OPERATOR: ______________________________________ OPERATIONS SUPERVISOR: _______________________________



10.4 Mobile Cranes 10.4.1 Introduction

This section describes the PCSB requirement related to the selection, inspection, maintenance and operation of mobile cranes. Reference made to DOSH & ASME B30.5 Mobile Type Cranes.

10.4.2 Contracted mobile crane requirements

Contracted equipment requirements are described by the terms of the Contract, which shall incorporate the requirements of this manual through appropriate reference to standards and regulations.

10.4.3 Mandatory Equipment and Safety Devices General mandatory devices and equipment

Cranes used in PCSB offshore & onshore facilities must be equipped with the following equipment, devices, and charts: • Cab shield or canopy to protect the operator from shifting or falling

materials (all mobile cranes with operator cabs or compartments), • Boom angle indicators, • Rated load capacity charts which include all boom configurations, • All mobile cranes must be equipped with an functional anti two-

blocking device and a load-moment or other load indicating system, • All mobile cranes must have stops provided on the boom to prevent

the possibility of over hoisting the boom, • Mobile cranes must be fitted with limit switches on hoist lines, • All mobile cranes shall be equipped with operable lights and horn, • All mobile cranes shall be equipped with an operable and properly

charged fire extinguisher, • All mobile crane hooks are to be labelled with their wire rope size,

their rated load capacity, and their weight, • All mobile crane hooks are to be fitted with safety latches.



By-Passing of Safety Devices

Cranes may be equipped with a variety of mechanical or electronic devices to aid the operator, provide information to the operator, or override the operator. Safety devices must never be routinely bypassed, defeated, or disabled. Examples of such safety devices are: • Anti two-block indicating and shutdown devices, which prevent the

load block or overhaul ball from coming too near the boom or jib tip, • Over booming devices, which prevent the boom from reaching a

predetermined maximum angle, • Load moment or rated capacity alarm and shutdown devices, which

warn or shutdown crane operations when overload situations are sensed.

Safety devices can only be bypassed for crane inspection, maintenance, and testing purposes. Authorization for bypass at any other time MUST: • Be driven by extreme circumstances, • Be supported by a risk-based analysis, • Be supported by a JHA and approved work procedures, • Be carried out under the supervision of a dedicated Crane /Lifting

Engineer.

10.4.4 Documentation

Documentation requirements

All lifts, inspections, testing, and maintenance for cranes shall be documented according to the following minimum requirements: • Pre-lift crane checks by certified crane operators should be

documented. • All mobile crane lifts shall be documented in the “Daily Crane

Operations Log Book”, • The crane contractor shall be responsible to provide and determine

the location where the log shall be located. The log is normally located in the cab of mobile cranes and designated areas for cranes without cabs or operating stations,

• The “Daily Crane Operations Log” records shall be retained for a minimum of one year by the crane contractor,

• Pre-use inspections of mobile cranes shall be documented and retained for a minimum period of 12 months by the crane contractor.

• Detailed mobile crane inspections for third party pre-qualification purposes should be retained by PCSB,

• Periodic inspections driven by industrial codes and regulatory requirements must be documented to substantiate compliance. The inspection and testing reports shall be documented by qualified PCSB inspectors or qualified third party inspection service contractors. These inspection and testing reports include, but are not necessarily limited to:

Copy of the Proof Load Test Certificate for the crane, Copy of the Proof Load Test Certificates for hook blocks, Copy of the Proof Load Test Certificates for wire ropes, Copy of the Proof Load Test Certificates for any rigging equipment

associated with the crane.



• These records shall be retained and made part of the permanent

crane record by the crane contractor. Additionally, a copy of the most recent periodic inspection must be readily available upon request.

• Written and dated maintenance and repair records will be retained for a period of two years.

• All crane incidents must be documented in compliance with the requirements of the PCSB Safety Management System.

The above applies to PCSB owned equipment as well as contractor owned equipment. The documentation of contracted crane suppliers shall be reviewed periodically by the Maintenance Support Group Superintendent or designated person.

10.4.5 Selection

Crane selection criteria

The selection of a crane for a particular lift starts with the determination of: • The calculated gross load weight, • The radius at which the load must be handled based on the best

position for the crane in relation to load pickup and drop points. A preliminary first choice of a crane is made based on the load and radius requirement. The selection process should always avoid critical lifts when practical and reasonable alternatives exist. Second analysis

A second analysis is carried out based on: • Type of crane (i.e. truck/rough terrain, • Available clearance, • Load dimensions, • Required lift height to determine boom length, jib length, and radius

necessary to maintain safe clearances, Note: If this radius conflicts with the first, repeat the process until the

radius figures agree • Nature of the load to be lifted, • Nature of the rigging or slinging to be used, • Where multiple cranes are used:

How the load is to be proportioned How the proportioning is to be maintained Whether the cranes have the appropriate capacity for the

proportioned load to be lifted \operating characteristics of the crane (speed of hoisting)

• Environmental factors, such as ground conditions and site weather. When this process is completed, determine the allowable load from the crane load chart and take the following actions:

• If the calculated gross load weight is less than the crane allowable load, site survey crane position and working radius; if all checks out, crane selection has been completed,

• If the calculated gross load weight is greater than the crane allowable load, select a crane with higher lifting capacity and repeat the above selection steps.



10.4.6 Inspection and Testing

Inspection classifications

Mobile cranes must be inspected in accordance with applicable regulatory requirements and intervals. Inspections may be conducted at more frequent intervals, as determined and guided by manufacturer recommendations, facility experience, and severity of the working environment. The following inspection requirements are based on ASME B30.5 “Mobile Cranes” and shall be applied to mobile cranes used at the PCSB facilities. The requirements are applied against three categories of mobile crane inspections: • Inspections of Cranes in regular use, • Inspections of Cranes not in regular use, • Initial Crane Inspections Inspections for cranes in regular use Inspection types

Inspection procedures for cranes in regular service (those with a continuous idle period of less than one month) are divided into two types based upon the intervals at which inspection should be performed. The inspection types are: • Frequent (pre-use), • Periodic. NOTE: Although inspection procedures for mobile cranes are divided

into two general categories based upon their usage, PCSB policy is that all mobile cranes are subject to a "Heavy Usage" inspection program. These inspections are not to be confused with the routine Planned Preventative Maintenance (PPM's).

Frequent inspections

Frequent (pre-use) inspections shall be conducted prior to each lifting operation. The inspection is performed by the crane operator and consists primarily of the operator conducting a crane walk-around and visual examination for any equipment defects that may present a direct bearing on either safety or the lifting operations. Periodic inspections

Periodic inspections shall be conducted at monthly intervals by a competent person or third party inspection service contractor recognized as qualified and meeting applicable regulatory qualification requirements. These inspections must be conducted at least monthly and are intended to determine the need for repair or replacement of components to keep the equipment in proper operating condition.



10.4.7 Frequent Inspections for cranes in regular use

Frequent inspection requirements and documentation

Items to be inspected as part of a “Pre-use Inspection” and wire rope inspections are itemized in ASME B30.5 “Mobile Cranes”. Any deficiencies shall be carefully examined and a determination made as to whether they constitute a safety hazard that requires immediate repair.

Frequent inspection summary

The following is a summary of Frequent, or Pre-use, Inspection requirements: 1. Check that all exposed moving parts are guarded.

2. Visually inspect each component of the crane used in lifting, swinging,

or lowering the load or boom for any defects that might result in unsafe operation. Inspect all wire rope (including standing ropes), sheaves, drums, rigging, hardware, and attachments. The visual wire rope inspection should cover the rope reasonably expected to be used that day, including rope termination, spooling on drums and any anchorage point. Remember that any hook that is deformed or cracked must be removed from service. Hooks with cracks, excessive throat openings of 15%, or hook twists of 10 degrees or more must be removed from service. Check for freedom of rotation of all swivels.

3. Visually inspect the boom and jib for straightness and any evidence of

physical damage, such as cracking, bending, or any other deformation of the welds. Look for corrosion under any attachments that are connected to the chords and lacing. Watch carefully for cracking or flaking of paint. This may indicate fatigue of the metal, which often precedes a failure. On lattice booms, look for bent lacing. If they are kinked or bent, the main chord can lose substantial support in that area. When lacing is bent, the ends also tend to draw together which pulls the main chords out of shape. This precaution is especially important on tubular booms where every component must be straight and free from any dents.

4. Do not attempt to straighten these members by hammering or heating

them and drawing them out. They must be cut out and replaced with lacing to the manufacturer's specifications, procedures, and approval.

5. Inspect tyres for cuts, tears, breaks, and proper inflation.

6. Visually inspect the crane for any air or hydraulic leaks.

7. Visually check that the crane is properly lubricated. The fuel,

lubricating oil, coolant and hydraulic oil reservoirs should be filled to proper levels.

8. Check that the crane is equipped with a fully charged fire extinguisher

and that the operator knows how to use it.



9. Observe good housekeeping and assure cab windows are clear and

free of cracks and windscreen wipers are in good condition. Insure crane structure is free from loose materials (i.e. tools) that have a potential to result in falling objects.

10. Check all functional operating mechanisms such as: sheaves, drums,

brakes, locking mechanisms, hooks, the boom, jib, hook rollers, brackets, outrigger components, limit switches, safety devices, hydraulic cylinders, instruments, and traffic and warning lights. Check the turntable connections for weld cracks and loose or missing bolts. If they are loose, there is a good chance that they have been stretched.

11. When checking the outriggers, be sure that neither the beams nor the

cylinders are distorted. Check that the welds are not cracked and that both the beams and cylinders extend and retract smoothly and hold the load. Check the condition of the floats/pad and check that they are securely attached.

12. Inspect and test all brakes and clutches for proper adjustment and

operation.

13. Always inspect boom hoist lockout and other operator aids such as anti-two-block devices (ATB) and load moment indicators (LMI), for proper operation.

14. While the engine is running, check all gauges and warning lights for

proper readings and operate all controls to see that they are functioning properly.

10.4.8 Periodic Inspections for cranes in regular use

Periodic inspection requirements and documentation

Items to be inspected as part of a “Periodic Inspection” and wire rope inspections are itemized in ASME B30.5 “Mobile Cranes.” Any deficiencies shall be carefully examined and a determination made as to whether they constitute a safety hazard that requires immediate repair. Periodic inspection summary

The following is a summary of Periodic Inspection requirements: 1. Carry out all elements of the “Pre-use Inspection.” The wire rope

inspection shall be expanded to cover a thorough inspection of the entire length of wire rope.

2. Inspect the entire crane for structural damage. Be careful to check for

distortion or cracks in mainframe, outrigger assemblies, and structural attachments between the superstructure and the carrier.

3. Inspect all welded connections for cracks. Inspect the main chords

and lacing (on lattice type booms) and other structural items for paint flaking and cracking which may indicate potential failure, as well as for dents, bends, abrasions, and corrosion. Check hydraulic booms for bending, side sway, or droop.



4. Check for deformed, cracked, or corroded members in the load/stress

bearing structure. Magnetic particle or other suitable crack detecting inspection should be performed at least once each year by an inspection agency retained by the owner. Inspection reports should be requested and retained in the crane file for a period of two years.

5. Inspect for cracked or worn sheaves and drums. 6. Inspect for worn, cracked, or distorted parts such as pins, bearings,

shafts, gears, rollers, locking devices, hook roller brackets, removable outrigger attachments lugs, and welds.

7. Inspect for excessive wear on brake and clutch system parts, linings,

pawls, and ratchets. 8. Inspect all indicators, including load and boom angle indicators, for

proper operation and calibration. 9. Inspect all prime movers for proper operation. 10. Inspect for excessive wear on drive sprockets and/or chain stretch (as

applicable). 11. Inspect for correct action of steering, braking, and locking devices. 12. Check that the counterweight is secure. 13. Check that the equipment tag number is permanently and legibly

marked. 14. Inspect all hydraulic and pneumatic hoses, fittings, and tubing. Any

deterioration of any system component should cause the inspector to question whether further use would constitute a safety hazard. Conditions such as the following require replacement of the part in question:

Any evidence of oil or air leaks on the surfaces of flexible hoses or at the point at which the hose in question joins the metal end couplings.

Any abnormal deformation of the outer covering of hydraulic hose, including any enlargement, local or otherwise.

Any leakage at connections that cannot be eliminated by normal tightening.

Any evidence of abrasive wear that could have reduced the pressure retaining capabilities of the hose or tube effected. The cause of the rubbing or abrasion must be immediately eliminated.



Records

The records for “Periodic Inspections” are recommended to be maintained for two years on critical items in use, such as brakes, crane hooks, and ropes. These inspection records should include, the date of inspection, the signature of the person who performed the inspection, and the tag number, or other identifier. This inspection record should be kept readily available for review. A detailed wire rope inspection report shall be kept on file as part of each “Periodic Inspection” report. This report documents condition of the wire rope to establish the basis for judging future inspection intervals and the basis for judging the proper time for rope replacement.

10.4.9 Inspections for cranes not in regular use Inspection types

Inspection procedures for cranes that are not in regular service are divided into two types based upon the length of time of the idle period. • Idle period of 1 to 6 months require an inspection conforming to the

requirements of “Pre-use Inspections” before being placed in service. All standby cranes should be inspected at least every 6 months or less.

• Idle period of over 6 months require an inspection conforming to the requirements of “Periodic Inspections” before being placed in service.

10.4.10 Initial Inspections

Requirements Prior to initial use at any PCSB facility, all new, altered, repaired, or one-time use cranes must have been inspected within the last 12 months by a competent person or third party inspection service contractor recognized as qualified and meeting applicable regulatory qualification requirements. Such cranes shall comply with the following requirements depending on whether they are sourced from a pre-qualified or non pre-qualified crane contractor: • Pre-qualified Crane Contractor: A copy of the most recent periodic

inspection report (no more that one year old) must be on record with the PCSB responsible person before bringing the crane on site. If the periodic inspection report is less than 6 months old, an inspection conforming to the requirements of “Pre-use Inspections” must be carried out before placing the crane in service, otherwise a “Periodic Inspection” must be carried out.

• Non pre-qualified Crane Suppliers: A copy of the most recent periodic inspection report (no more that one year old) must be on record with the PCSB responsible person before bringing the crane on site. In all cases, an inspection conforming to the requirements of “Periodic Inspections” must be carried out before placing the crane in service.



10.4.11 Testing

Inspection types

Mobile cranes shall be load tested only in accordance with the manufacturer’s specifications and limitations and ASME B30.5 Mobile Cranes. Key elements of the load testing process are as follows: • Operational testing followed by load testing shall occur prior to initial

use of all cranes in which load sustaining parts (boom, slew ring, heel pin, boom cylinder, etc) have been altered, replaced, or repaired.

NOTE: If the replacement wire rope is provided with a Test Certificate, it is specifically excluded from load test requirements. No wire rope shall be used unless provided with a Test Certificate. When the wire rope is replaced, an operational functional test under normal operating load should be made prior to putting the crane back in service.

• Test loads shall not exceed 110% of the crane manufacturer’s rated load.

• Load testing shall be conducted and documented under the direction of a competent person or third party inspection service contractor recognized as qualified and meeting applicable regulatory qualification requirements.

No cranes shall be re-rated in excess of the original crane load ratings unless the crane manufacturer approves such rating changes.

10.4.12 Proof Load Testing for Personnel Handling

Purpose

The purpose of the following is to state PCSB philosophy on periodic proof load testing of mobile cranes and the requirement of a "stripdown" inspection of crane mounted hoists, which are used in the handling of personnel. Application

This section applies to all mobile cranes and personnel handling hoists/winches. Philosophy

This section shall maintain consistency with the requirements of ASME B30.5 and applicable manufacturer's recommendations. Key requirements

A crane proof load test is required under the following conditions: • A new crane being placed into service, • After major repair or alteration of a critical component i.e. replacement

of a hoist, boom cylinder, slew ring, etc, • A stripdown inspection of personnel handling hoist is required after

2500 hours of use or 36 months whichever comes first if the hoist is serviced under a comprehensive preventative maintenance program.



Proof load testing

With respect to PCSB cranes involved in personnel handling operations, PCSB recommendations are that: • Dynamic load testing (utilizing water weights or solid weights) is

conducted, which provides for the crane to be boomed in and out, hoisted and slewed; however, it is also recognized that this method is not always practical due to the availability of equipment,

• A proof load test is carried out every 3 years, which would fall into line with the stripdown inspection of personnel handling hoists.

Stripdown – Inspection

With respect to stripdown inspections for personnel handling cranes covered in this section: 1. Personnel handling hoists should undergo a "stripdown" inspection in

a workshop, 2. A "stripdown" inspection will include the hoist being completely

disassembled, cleaned, and inspected, and the replacement of all worn, cracked, corroded or distorted parts such as pins, bearings, shafts, gears, brake rotors, brake plates, drum and base,

3. The stocking of replacement parts shall be regarded as essential to this procedure,

4. The rebuilt hoist will be line pull tested to the rated load, 5. After inspection, rebuild, and testing, a new certificate for personnel

handling will be issued be a competent lifting equipment examiner, 6. A personnel handling hoist register shall be kept so that each hoist

can be traced and the date of when the hoist was put into service is recorded and to which crane the hoist is fitted.

Additional

During the "stripdown" inspection of personnel handling hoists, it is recommended that the hoist wire rope be changed out.

10.4.13 Maintenance


All mobile cranes shall have programmed maintenance programs established based on the crane manufacturer’s recommendations. The programmed maintenance shall: • Be documented in accordance to the work order reporting

requirements or endorsed contractor systems, • Utilize replacement parts obtained from the original equipment

manufacturer as a recommended practice.



Adjustments and repairs

Any hazardous conditions reported, as a result of frequent (pre-use) inspections or periodic inspections shall be corrected before the crane is returned to service. Repair activities must: • Include actions and procedures to properly prepare the crane so that it

can be worked on safely (i.e., appropriate shop or yard space, controls in safe positions or locks/warning signs applied, starting rendered inoperative, prime mover secured, boom and blocks properly secured, hydraulic systems relieved of pressure, etc.),

• Be carried out by competent and designated Crane Service Contractor personnel,

• Include actions and procedures to properly re-commission the crane and return it to service (i.e., re-install all guards, bleed hydraulic systems, safety devices re-activated, maintenance equipment removed, testing requirements met, etc.)

Lubrication

All moving parts of the crane for which lubricant is specified should be regularly lubricated as follows: • All lubrication points specified by the crane manufacturer regarding

type of lubricant, frequency, and maintenance of levels, • Lubricating systems should be checked for proper delivery of

lubricant, • Unless equipped for automatic or remote lubrication or appropriate

protection is applied, the crane must be stationary while lubrication is performed.

10.4.14 Operation

References and standards

The basic elements governing safe crane operations are summarized in the ASME B30.5 “Mobile Cranes” for further and complete information concerning mobile crane operations requirements, practices, and guidelines.

Operations requirements, practices, and guidelines

All crane operations in PCSB facilities must be in compliance with the following: • Operator qualification requirements, • Lift planning, scheduling, and execution activity requirements of the

PCSB lifting process, • Safe Crane Operations guidelines. Refer to ASME B30.5 for further details and information concerning crane operating practices and the operation near electrical power hazards.



10.4.15 Standard mobile crane signals

Mobile crane signal practices shall conform to the standard hand signals illustrated in ASME B30.5 “Mobile Cranes, unless voice communication means (telephone, radio, or equivalent) are used. Regardless of the method: • Signals/communications must be clearly discernible or clearly audible

at all times, • No response shall be made unless signals are clearly understood, • Standard hand signals shall be posted conspicuously on/in all cranes, • When moving the vehicle, the following audible signals should be

used: • STOP-one audible signal • GO AHEAD-two audible signals • BACK UP- three audible signals, and • If it is desired to give instructions to the operator, other than those

provided by the established signal system, all crane motions shall come to a stop.



REFERENCE: ASME B30.5 “Mobile Cranes,”

Chapter 5-3, “Operation”. Hand signals Hand communications shall be consistent with standard convention, agreed upon in advance of the operation, and used by all personnel involved in the lifting operations. Forms

Attachment 1 Example of a Mobile Crane Selection Checklist for use by a lift planner or a designated person.

Attachment 2 Example of a Mobile Crane Operators Daily Inspection Report Form. This format, a manufacturer's format, or a company endorsed contractor format, should be utilized to comply with individual mobile crane frequent inspection requirements. No formal format for wire rope inspection is required except as itemized on the attachment.

Attachment 3 Example of a Mobile Crane Detailed Inspection Report. This format, a manufacturer’s format, or a company endorsed contractor format, may be utilized to comply with individual mobile crane periodic inspection requirements. Attachment 4 Example of a Mobile Crane Safety Check/Service Checklist Attachment 5 Example of a Mobile Crane Inspection Report Attachment 6 Example of a Mobile Crane Operators Maintenance Inspection Report Attachment 7 ASME & API Recognized Hand Signals



Attachment 1 – Example of a Mobile Crane Selection Checklist

Mobile Crane Selection Checklist Item Description Check1. Determine weight of load, rigging, etc., to be listed, height of lift and

dimension of load.

Assess plan drawings (layout considerations).

Determine where load is to be landed.

Determine where load is to be picked up.

Select position for crane.

2.

Check clearances.

3. Determine maximum working radius and make a first-choice of a crane based on load/radius and terrain requirements.

4. Assess elevation drawings. Elevation details can often be plotted to scale on the crane manufacturer's "Range Diagram" - a drawing showing the range of boom lengths and boom angles for various crane configurations. Check clearances based on load dimensions and required lift height.

5. Determine boom length, jib length, and radius necessary to maintain clearances.

6. Adjust working radius, if necessary; return to item 2 (above) if radius changes, and work through list again.

7. Determine allowable load from crane load chart.

8. If load weight is greater than allowable, choose a greater capacity crane and repeat process from item 2 (above).

If load weight is less than allowable, go into field and verify actual crane position and working radius.

For Dual Lifts: 1. How load is to be proportioned. 2. How load proportioning is to be maintained.

3. Is crane load proportional to crane capacity? 4. Operating characteristics of each crane (i.e. hoist speed). 5. Environmental factors (i.e. weather conditions).



Attachment 2 – Example Mobile Crane Operators Daily Inspection Form

Operator’s Name: Date:

Supervisor: Equipment Number: Machine Due for Service:

Checklist Pre-Operation Boom

Proper Tire Inflation/Condition No Cracks In Boom Engine Oil Level Boom Pendant Pins Fuel Levels Jib and Sheaves Cab Glass Jib Stops Cowling Around Moving

Machinery Wire Rope and Clips

Deck and Walkway Clear of Hazards

Wedge Sockets

Lubricant in Pump Drive Gearboxes

Linkages, Pins, Swivels, etc in Place

Drain Valves on Air Tanks Closed Hooks Swing Area Barricaded

Checklist In Cab Exterior Drum Brakes No Outrigger Hydraulic Leaks Swing Brakes Counterweights Secure Travel Brakes All Lights Operational Boom Hoist No Engine Oil Leaks Proper Operation of Controls Engine Coolant Levels Wipers Engine, Torque Converter, Hydraulic Warning Devices, Horns, etc System Fluid Levels Automatic Boom Hoist Kick Out Hydraulic Lines and Motors All Gauges (air, oil, hour, temp),

Meters No Leaks in Air Lines and Air Brakes

Fire Extinguisher Air Pulleys and Belts Hydraulic Oil Reservoir Hydraulic Hoses Anti-Two Block Device Working No Open Gears Load Cells Working No Exposed Electrical Connections Load Moment Indicator Working All Compressed Air Tanks Drained All Limit Switches Working Slings Crane Is Level Other Cab Is Clean Load Chart In Cab Operator’s Comments on Machine Condition (write down and describe all deficiencies):

Operator Signature

Supervisor Signature



Attachment 3 – Example Mobile Crane Detailed Inspection Report Mobile Crane Selection Checklist Item Description Check1. Determine weight of load, rigging, etc., to be listed, height of lift and

dimension of load.

Assess plan drawings (layout considerations). Determine where load is to be landed. Determine where load is to be picked up. Select position for crane.

2.

Check clearances. 3. Determine maximum working radius and make a first-choice of a

crane based on load/radius requirements.

4. Assess elevation drawings. Elevation details can often be plotted to scale on the crane manufacturer's "Range Diagram" - a drawing showing the range of boom lengths and boom angles for various crane configurations. Check clearances based on load dimensions and required lift height.

5. Determine boom length, jib length, and radius necessary to maintain clearances.

6. Adjust working radius, if necessary; return to item 2 (above) if radius changes, and work through list again.

7. Determine allowable load from crane load chart. If load weight is greater than allowable, choose a larger

crane and repeat process from item 2 (above). 8.

If load weight is less than allowable, go into field and verify actual crane position and working radius.

For Dual Lifts:

1. Determine how load is to be proportioned.

2. Determine how load proportioning is to be maintained.

3. Determine if the crane load (for each crane) is proportional to its rated capacity.

4. Determine if each crane has suitable operating characteristics (such as hoist speed) for the proposed lift.

5. Consider the environmental factors for each crane, such as weather and ground conditions, in the working area.



Attachment 4 – Mobile Crane Safety Check/Service Checklist

CRANE SAFETY CHECK/SERVICE CHECKLIST

JOB NO: CODE:

DATE: √ Serviceable UNIT TYPE: X Unserviceable UNIT HOURS:

R Serviceable But Needs Repair

LOCATION: N/A Not Applicable NO DIESEL ENGINE CODE NO GENERAL CODE 1 Drain lube oil & refill to correct level 32 Check drive axle oil 2 Change lube oil filter & replace filter

seal rings 33 Check hydraulic oil

3 Start engine & run slowly until oil pressure reaches normal working pressure

34 Check brake fluid

4 Stop engine check oil level & top up 35 Check & adjust brakes 5 Remove fuel filters 36 Check steer axle, steering box & ball joints 6 Fill replacement filters with fuel & fit to

unit 32 Check wheel nuts are tight

7 Drain condensation from bottom of fuel tank

33 Carry out general lubrication, grease all nipple

8 Bleed fuel system through 34 Check operation of horn 9 Check air filters & clean or replace as

req. 35 General appearance of crane

10 Check coolant level & anti-freeze strength top up anti-freeze to 25-30% if below this level

CHECKED BY (INITIALS)

11 Examine the radiator core & steam clean if req.

12 Change coolant filter if fitted NO CRANE & MAST CODE 13 Examine & adjust or change V belts as

required 36 Extend rope & check & lubricate

14 Check & grease fan hub assembly 37 Extend mast fully & check & lubricate 38 Check & lubricate mask extension chain 15 Lubricate all other points 39 Check main ram condition & pin security

16 Run unit & check all systems for leaks 41 Check & lubricate hook & travelling block 42 Check & lubricate mast pilot pin CHECKED BY (INITIALS) 43 Check & lubricate slew ring & gear

44 Check & test anti-two-block No BATTERY CODE 45 Check & test safe load indicator 17 Top up Battery 46 Check & lubricate outrigger beams 18 Check charging system 47 Check outrigger rams for leaks 19 Check starter motor for security 48 Check function of all lights 20 Check starter system for defects 49 Check air system for hydraulic leaks



No TRANSMISSION CODE TYRE PRESSURES

21 Check level condition or lube oil for visible signs of contamination

N/S O/S

22 Change filters (& clean suction screen if oil is being changed

Drive Axle

PSI PSI PSI PSI

23 Run unit & check for leaks Steel Axle

PSI PSI

24 Function test transmission in all gears & check the correct operation


25 Check the selector has no pressure on it in each gear the clevis pin should rotate freely

26 Check transmission breather is clean & in good condition




TYRE CONDITIONS No Drive Shafts Code N/S O/S

27 Check flange bolts are tight Drive Axle 28 Check hardy spicer for wear Steel Axle 29 Check splines for wear & shaft for any

damage

30 Grease hardy spicer until grease comes out clear this to purge burnt grease & Rem dirt

31 Grease splines


MAJOR WORK INSTRUCTIONS

ITEM CODE DETAILS OF WORK

REQUIRED DETAILS OF WORK DONE

DATE NCR NO.

INIT.

Parts Required Item No.

Description Quantity Specification Priority

Priority 1 – Crane out of service Priority 2 – Limited use of crane Priority 3 – Crane can still be used

ENGINEER SUPERVISOR

PRINT NAME PRINT NAME

SIGNATURE SIGNATURE

DATE DATE



Attachment 5 – Mobile Crane Inspection Report

MOBILE CRANE INSPECTION REPORT Report No.:

Job No.: Client Name: Job Officer: Report Date:

Job Description:

Model: Serial No.: Reg No.: Hours carrier: Mileage Superstructure: Inspection date:

Location:

N.B. All items must be recorded with a " “ Items not applicable are

marked " N/A " Section 1: Jibs And Fittings Pass Rework CCOOMMMMEENNTTSS

1.1 Main Jib Structure 1.2 Hoist Rope Reeving 1.3 Hook Block 1.4 Sheaves - Pins and Keepers Plates 1.5 Angle/ Radius Indicator 1.6 Telescopic Jib 1.6.1 Wear Pads 1.6.2 Telescoping Ram 1.6.3 Extension and Retraction Chains 1.6.4 Lock Valves 1.6.5 Manual Extension Equipment 1.7 Fly Jib 1.7.1 Structure and Mast 1.7.2 Stowage and Pins 1.7.3 Sheaves - Pins and Keeper

Plates

Comments: Section 2 : Derrick Pass Rework Comments 2.1 Rams and Anchor Pins 2.2 Lock Valves Pipes and Fittings Comments:



Section 3 : Main Hoist Pass Rework Comments 3.1 Motor 3.2 Brake 3.3 Reduction Unit 3.4 Barrel and Rope Anchorage 3.5 Rope 3.6 Limit Switch Comments: Section 4 : Slew Pass Rework Comments 4.1 Motor 4.2 Brake 4.3 Reduction Unit 4.4 Rotary Coupling 4.5 Slew Lock Pin 4.6 Slew Pinion Ring and Bolts Comments: Section 5 : Superstructure Pass Rework Comments 5.1 Superstructure Frame 5.2 Sheaves and Pin 5.3 Ballast Weight & Securing Bolts & Pins 5.4 Ballast Removal Rams etc 5.5 Panelling Comments: Section 6 : Engine Carrier Pass Rework Comments 6.1 Engine 6.2 Stop Control 6.3 Cooling System 6.4 Charging System and Batteries 6.5 Fuel System Throttle and Tank 6.6 Exhaust System and Mountings Comments:



Section 7 :Engine Superstructure Pass Rework Comments 7.1 Engine 7.2 Stop Control 7.3 Cooling System 7.4 Charging System and Batteries 7.5 Fuel System Throttle and Tank 7.6 Exhaust System and Mountings Comments: Section 8 : Axle Pass Rework Comments 8.1 Hubs 8.2 Stub Axle and King Pins 8.3 Wheel Nuts 8.4 Axle Bolts and Axle Locks 8.5 Springs and Shock Absorbers Comments: Section 9 : Steering Pass Rework Comments 9.1 Wormbox and Column 9.2 Drop Steering and Track Arms 9.3 Drop Link and Track Rod (s) 9.4 Pump Tank Hoses and Rams Comments: Section 10 : Hydraulic System Pass Rework Comments 10.1 Pump and Drive 10.2 Filters 10.3 Tank 10.4 Control Valve Banks and Linkage 10.5 Hoses and Fittings 10.6 Outriggers Rams and Lock Valves 10.7 Axle Lock Rams and Valves 10.8 Counterbalance Valves Comments: Section 11 : Air System Pass Rework Comments 11.1 Compression and Drive 11.2 Reservoir Water Trap & Antifreeze 11.3 Piping Hoses and Fittings Comments:



Section 12 : Road Braking System Pass Rework Comments 12.1 Fluid Level 12.2 Pipework Cables Fitting etc 12.3 Cylinders - Valves and Servos 12.4 Parking Brake and Linkage 12.5 Adjustments and Operations Comments: Section 13 : Transmissions & Drive

Axle Pass Rework Comments

13.1 Gearbox & Torque Converter 13.2 Clutch Fluid Level 13.3 Auxiliary Gearbox & P.T.O. 13.4 Differential (s) 13.5 Propshaft & Midshaft Bearing 13.6 Hubs 13.7 Wheel Nuts 13.8 Springs 13.9 'U' Bolt and Axle Locks 13.10 Bogie Beams and Suspension Comments: Section 14 : Electrical System Pass Rework Comments

14.1 Lights 14.2 Windscreen Wipers and Washers 14.3 Direction Indicators 14.4 Switches 14.5 Wiring 14.6 Horn and Heaters Comments: Section 15 : Safe Load Indicator Pass Rework Comments 15.1 Check Operation with Load Comments: Section 16 : Auxiliary Equipment Pass Rework Comments 16.1 16.2 16.3 16.4 16.5 Comments:



Section 17 : General Condition Pass Rework Comments 17.1 Cleanliness 17.2 Servicing 17.3 Other Remarks: 17.4 17.5 17.6 17.7 17.8 17.9 17.10 Comments: Inspection Report:

Engineer

Name:

Signature: Date:



Attachment 6 – Mobile Crane Operators Maintenance Inspection Report CRAWLER/ MOBILE CRANE OPERATORS MAINTENANCE INSPECTION REPORT

Report No.:


Job Description:

Model: Serial No.: Reg No.: Hours carrier: Mileage Superstructure: Inspection date:

Location:

N.B. All items must be recorded with a " “ Items not applicable are

marked " N/A " Section 1 : Daily Checks Pass Rework Comments 1.1 Engine Oil 1.2 Fuel 1.3 Coolant 1.4 Torque convectors (if fitted) 1.5 Drain air tanks 1.6 Tyres and pressures 1.7 Wheel studs 1.8 Operation of A.S.L.I. 1.9 Inspect ropes for spooling and kinks 1.10 Operation of overhoist limits (if fitted) 1.11 Correct operation of controls 1.12 Fly jib assembly 1.13 Jib pendant ropes and pins 1.14 General cleanliness of crane and decking 1.15 Debris between twin wheels 1.16 Operation of slew lock pin and slewring

brake

1.17 Cab gauges 1.18 Torque converter 1.19 Hydraulic accumulator Comments:



Section 2 :Weekly Checks Pass Rework Comments 2.1 Fan belt tension 2.2 Battery acid/ water level 2.3 Lubricants in transmission 2.4 Brake and clutch reservoirs 2.5 Steering and throttle reservoirs 2.6 Windscreen washer reservoirs 2.7 Fuel system water trap 2.8 Lubricate all grease nipples as per

manufacturers handbook

2.9 Hydraulic oil tank 2.10 Winch oil 2.11 Lubricate all sheaves, shafts & active

linkages

2.12 Boom and ram pivot pins 2.13 Lubricate ropes 2.14 Slew ring path 2.15 Labelling of controls 2.16 Hook block safety catches 2.17 General safe assembly operation of boom 2.18 Rope anchorage and pins 2.19 Outrigger floats 2.20 Outrigger timber packers 2.21 Cab Heater 2.22 Engine running hours 2.23 Super Structure 2.24 Chassis Comments: Section 3 : Equipment With Machine No. Size Comments 3.1 Hookblocks 3.2 Boom section (if applicable) 3.3 Fly jib and section 3.4 Overhoist fly unit 3.5 Chains, slings, shackles (state serial

numbers)

3.6 Comments:



Section 4 : Certification Check Comments 4.1 4yr test certificates 4.2 Thorough exam. certificates 4.3 Tackle certificates 4.4 Crane manual Comments: Automatic Safe Load Indicator Comments Please test the S.L.I. with a known weight once in every working week.

Date of test Boom length Weight Radius In correct order

REQUIREMENT You are required to examine as far as construction permits the working gear, anchorages, automatic safe load indicator, derricking interlock, and other safety devices weekly. Please enter here the result of your inspection stating if in good order:__________________ Requirements, oils, grease, etc: Operator Name: Date:

Operator Signature: Date:

Manager/ Supervisor Name: Date:

Manager/ Supervisor Signature: Date:



Attachment 7 – ASME/API Hand Signals As per Hand Signals on Page 102 with the exception of these below which show the signals for extending and retracting the boom.



10.5 Overhead and Gantry Cranes 10.5.1 Introduction

This section describes the PCSB requirement related to the selection, inspection, maintenance and operation of overhead and gantry cranes.

10.5.2 Selection Selection and use criteria

Overhead and gantry cranes are designed and installed as permanent equipment to serve the lifting needs of their service locations. In this sense there is no selection process as with mobile cranes and the lift planner or crane operator makes a yes/no decision to use these cranes based strictly on the following: • Crane suitability for the lift, • Rated capacity of the crane, • Gross weight of the load, • Lift classification and lift plan requirements.

10.5.3 Inspection Inspection classifications

Gantry and overhead cranes must be inspected in accordance to applicable regulatory requirements and intervals. Inspections may be conducted at more frequent intervals, as determined and guided by manufacturer recommendations, facility experience, and severity of the working environment. The following inspection requirements are based on ASME B30.17 “Overhead and Gantry Cranes” and shall be applied to overhead and gantry cranes used at any PCSB facility. The requirements are applied against three categories of crane inspections: • Inspections of Cranes in regular use, • Inspections of Cranes not in regular use, • Initial Crane Inspections.

10.5.4 Inspections for Cranes in Regular Use Inspection types

Inspection procedures for cranes in regular service (those with a continuous idle period of less than one month) are divided into two types based upon the intervals at which inspection should be performed. The inspection types are: • Frequent (pre-use), • Periodic. Frequent (pre-use) inspections

Frequent, or pre-use, inspections shall be conducted prior to each lifting operation. The inspection is performed by the crane operator and consists primarily of the operator conducting a crane walk-around and visual examination for any equipment defects that may present a direct bearing on either safety or the lifting operations.



Periodic inspections

Periodic inspections shall be conducted at monthly intervals by a competent person from the Crane Service Contractor recognized as competent and meeting applicable regulatory qualification requirements. These inspections must be conducted at least monthly and are intended to determine the need for repair or replacement of components to keep the machine in proper operating condition. Frequent Inspections for cranes in regular use Frequent (pre-use) inspection requirements and documentation

Items to be inspected as part of Frequent (Pre-use) Inspection and wire rope inspections are itemized in ASME B30.17 “Overhead and Gantry Cranes”. Competent persons shall carefully examine any deficiencies and make a determination as to whether they constitute a safety hazard that requires a more detailed inspection or immediate repair. Frequent inspection shall include observations during operation. Frequent (pre-use) inspection summary

The following is a summary of the frequent, or pre-use, inspection. Items such as the following shall be inspected by operators before and during each lift: • Surface of the load for debris, • Condition and operation of controls, • Condition and operation of indicators and meters, when installed, • Visual check that wires rope is spooling correctly, • Inspect operating mechanisms for proper operation, proper

adjustment, and unusual noise, • Check hoist upper limit switch, • Look for deterioration or leakage in lines, tanks, valves, drain pumps,

and other parts of air or hydraulic systems, • Visually inspect the hook for deformation and hook latches, • Check the hoist rope for kinking, crushing, bird caging, corrosion and

end connections, • Check the hoist rope for proper spooling onto the drum(s) and

sheave(s), and • Hoist chain visual inspection for nicks, gouges, stretch or distortion,

wear, and corrosion. A checklist based on the particular crane manufacturers format and requirements should be utilized to assist the gantry or overhead crane operator to conduct frequent inspection. Records shall be maintained for at least two years at the location, or longer at the discretion of the PCSB Responsible Person. Reports

A checklist based on the particular crane manufacturer format and requirements should be utilized to assist the gantry or overhead crane operator to conduct frequent inspection. Records shall be maintained for at least two years at the location.



10.5.5 Periodic Inspections for cranes in regular use

Periodic inspection requirements and documentation

Items to be inspected as part of a Periodic Inspection and wire rope inspections are itemized in ASME B30.17 “Overhead and Gantry Cranes”. Competent persons shall carefully examine any deficiencies and make a determination as to whether they constitute a safety hazard that requires a more detailed inspection or immediate repair. Periodic shall include observations during operation. Periodic inspection summary

The following is a summary of Periodic Inspection requirements: • Perform all elements of the Frequent Inspection, • Conduct and complete formal inspection reports for:

Hooks for deformation and cracking and hook latches for integrity, Hoist rope and end connections (entire length of rope), and Hoisting chains,

• Check for deformed, cracked or corroded structural members, • Check for loose or missing bolts, nuts, pins, or rivets, • Check for cracked or worn sheaves and drums, • Check for worn, cracked, or distorted parts such as pins, bearings,

wheels, shafts, gears rollers, locking and clamping devices, bumpers and stops,

• Check for excessive wear of brake system parts, excessive wear of drive chains, sprockets and chain stretch,

• Check for deterioration of controllers, master switch contacts, limit switches and push-button stations, but not limited to these items,

• Check gasoline, diesel, electric, or other power plants for proper operation,

• Check motion limit devices that interrupt power or cause a warning to be activated,

• Check rope reeving for compliance with recommendations of the crane manufacturer,

• Check all function, instruction, caution, and warning labels or plates for legibility and need for replacement,

• Check that load block capacities are marked on both sides. Markings shall be legible from the ground floor,

• Check that fire extinguisher are in cranes with cabs, where applicable, • Check warning devices and audible alarms, • Insure that there are no over runs when control is released, • Insure that there is no load slippage. A checklist based on the particular crane manufacturers format and requirements should be utilized to assist the gantry or overhead crane operator to conduct frequent inspection requirements. Record retention is required and becomes a permanent part of the equipment record. Reports A checklist based on the particular crane manufacturer format and requirements should be utilized to assist the gantry or overhead crane operator to conduct frequent inspection. Records shall be maintained for at least two years at the location. See Attachment 1 – Overhead/Pillar Crane Inspection Report



10.5.6 Testing

Gantry and overhead cranes shall be operationally tested and load tested only in accordance with the manufacturer’s specifications and limitations and ASME B30.17, Overhead and Gantry Cranes. Key elements of the testing process are as follows: • Operational testing followed by load testing shall occur prior to initial

use of all cranes in which load sustaining parts have been altered, replaced, or repaired,

NOTE: The replacement of load chain and wire rope are specifically excluded from load test requirements, however, an operational functional test under normal operating load shall be made prior to putting the crane back in service.

• Test loads shall not exceed 125% of the crane manufacturers load rating,

• Load testing shall be conducted and documented under the direction of a competent person from the Crane Service Contractor recognized as qualified and meeting applicable regulatory qualification requirements,

• No cranes shall be re-rated in excess of the original crane load ratings unless approved by the crane manufacturer.

10.5.7 Proof Load Testing

Purpose

The purpose of the following is to state PCSB philosophy on periodic proof load testing of overhead and gantry cranes. Application

This section applies to all overhead and gantry cranes, used onshore or offshore. Philosophy

This section shall maintain consistency with the requirements of ASME B30.17, Overhead and Gantry Cranes and applicable manufacturer's recommendations. Key requirements

A crane proof load test is required under the following conditions: • A new crane being placed into service, • Cranes that are being permanently relocated, • After major repair or alteration of a load suspension part. Proof load testing

With respect to PCSB cranes, PCSB recommendations are that: Dynamic load testing (utilizing water weights or solid weights) is conducted, which provides for the crane to be hoisted, lowered, and traversed. However, it is also recognized that this method is not always practical due to the availability of equipment.



10.5.8 Maintenance


All overhead and gantry cranes shall have programmed maintenance programs developed and implemented based on the crane manufacturer recommendations. The programmed maintenance shall: • Be documented in accordance to the work order reporting

requirements of the endorsed contractor systems, • Utilize replacement parts obtained from the crane & lifting contractor

or original equipment manufacturer as a recommended practice. Adjustments and Repairs

Any hazardous conditions reported as a result of pre-lift inspections, frequent inspections, or periodic inspections shall be corrected before the crane is returned to service. Repair activities must: • Include applicable actions and procedures to properly prepare the

crane so that it can be worked on safely. Examples of such actions include:

Adequate inspection space and other access, Controls in off positions or locks/warning signs applied, Warning signs and barriers in place beneath the crane, Full time watch/signal person to prevent interference from other

operations, Starting rendered inoperative, Boom and blocks properly secured, Hydraulic systems relieved, Runway barriers in place, and Tag/lockouts in place,

• Be carried out by competent and designated Crane & Lifting Contractor Personnel,

• Include actions and procedures to properly re-commission the crane

and return it to service. Examples of such actions include:

Re-install all guards, Bleed hydraulic systems, Safety devices re-activated, Maintenance equipment removed, Testing requirements met.

Lubrication

All moving parts of the crane for which lubricant is specified should be regularly lubricated as follows: • All lubrication points specified by the crane manufacturer regarding

type of lubricant, frequency, and maintenance of levels, • Lubricating systems should be checked for proper delivery of

lubricant, • Unless equipped for automatic or remote lubrication or appropriate

protection is applied, the crane must be stationary while lubrication is performed.



10.5.9 Operation

Introduction

Although overhead and gantry cranes must be operated in accordance to the manufacturer’s operating instructions, operators must be further guided by the operating procedures and cautions detailed in ASME B30.17, Overhead and Gantry Cranes. This section provides a summary of key basic operating guidelines and precautions. Concerns unique to overhead and gantry cranes

Due to the nature, design, and load motion characteristics of these cranes, the following operational items should be noted: • The operator should test the hoist brake each time a load approaching

the rated capacity is handled by raising the load a few inches and applying the brake; any slippage or downward motion is unacceptable,

• Side pulls must not be permitted, • During hoisting or travel there must be no sudden acceleration or

deceleration of the moving load, • If crane has more than one speed, always start in slowest speed, • Never change directions without allowing crane motor to stop. Other operating procedures and precautions are as follows: • Operators must be considered competent by the Operations

Supervisor to operate overhead and gantry cranes at that location, • The hook should be brought over the load in such a manner as to

minimize swinging, • Ensure the rope is seated in the drum grooves and in the sheaves (i.e.

check for the signs of slack rope conditions), • The load should be moved smoothly, slowly, and never contact any

obstructions, • The operator shall not lift, lower, or travel the crane while anyone is on

the load or hook, • The load should not be lowered below the point where two wraps of

rope remain on each anchorage of the hoisting drum unless a lower limit device is provided, in which case no less than one wrap shall remain,

• The operator should not leave the position at the controls while the load is suspended over an area accessible to personnel,

• Prior to initial use of any hoist during each shift or day, the operator should perform the Frequent, or Pre-Use, Inspection and notify the supervisor of any hazardous defects immediately,

• The hoist upper limit device that controls the upper limit of travel of the load block should never be used as an operating control in normal operation unless additional backup means are provided to prevent damage from over-travel,

• Hand signals should be posted conspicuously at the work location.



Attachment 1 – Overhead/Pillar Crane Inspection Report OVERHEAD/ PILLAR CRANE INSPECTION REPORT Report No.:


Job Description:

Equipment Make & Model:

SWL:

Type: S/No.: No. Items To Inspect Remarks/ Details

1 Test Run 2 Isolator

3 Pendant Cable

4 Control Box

E 5 Control Buttons

L 6 Festoon Cables

E 7 Festoon Track

C 8 Festoon Trolleys

T 9 Contactors/ Controllers

R 10 Segments/ Tips

I 11 Overloads

C 12 Timers

A 13 Motor Brush(s)/ Rings

L 14 Limits

15 Resistance

16 Collectors/ Shoes

17 General Wiring

B 18 Linings R 19 Laminations

A 20 Fixing Pins

K 21 Drum

E 22 Shaft/ Keyways

S 23 Coils 24 Wheels

25 Flanges/ Treads

26 Gears

27 Pinions

28 Bush/ Bearings

M 29 Coupling/ Bushes

E 30 Gearboxes

C 31 Oil Levels

H 32 Line Shaft/ Keyways

A 33 Load Rope/ Chain

N 34 Guide/ Pressure Band

I 35 Return Sheaves

C 36 Bottom Block Bushes/

A 37 Cross Head

L 38 Top Hook/ Bottom Hook

39 Safety Catch

40 Load Sprocket

41 Hand Chain/ Wheel

42 General Structure

43 Bridge Rails

44 Lubrication Engineers Confirmation: 1. The above inspection has been *completed/ progressed. 2. The CRANE is *Returned to / Taken out of SERVICE (*Delete as applicable) Engineer Sign: Print: Date:



10.6 Forklifts 10.6.1 Introduction

This section describes the PCSB requirements related to the selection, inspection, maintenance and operation of forklifts.

10.6.2 General Responsibilities Supervisor

It is the responsibility of the Supervisor for the work area where the fork lift is operated to ensure that: • Only trained and competent personnel operate the fork lifts, • Fork lift inspections and necessary repairs are completed and

documented, • All equipment documentation is in accordance with the appropriate

standards. Operator

It is the responsibility of the Operator to: • Conduct forklift pre-use inspection before the equipment is operated, • Document and report all defects found to the Supervisor, • Follow safe operating procedures when operating the equipment.

10.6.3 Operator Pre-Qualification Minimums

All operators must meet the following physical requirements: • Must have no adverse vision problems that cannot be corrected by

glasses or contacts, • Must have no adverse hearing loss that cannot be corrected with

hearing aids, • Must have no physical impairments that would hinder safe operation

of the forklift, • Must have no neurological disorders that affect balance or

consciousness, • Must not be taking any medications that affect perception, vision, or

physical abilities.

10.6.4 Documentation All lift truck inspections and necessary repairs must be documented.



10.6.5 Training

General requirements

The general requirements for forklift training are as follows: • Training for operators shall be conducted by a competent instructor,

from the crane & lifting contractor and shall be conducted under close supervision,

• All training and evaluation must be completed before an operator is permitted to use a powered forklift without continual and close supervision,

• Training content will consist of a combination of formal instruction, practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator’s performance in the workplace.

10.6.6 Selection

Selection criteria

Forklifts must meet the design specifications set forth in ASME B56.10 2001 or equivalent. Certification of conformity with this standard should be marked clearly on the vehicle nameplate. Other nameplate data

In addition to the standards compliance information mentioned above, the nameplate should be clearly marked with: • The identity of the lifting attachment(s), • The approximate weight of the truck/attachment combination, • The load capacity of the truck with attachment at maximum elevation

and the load laterally centered. Safety fittings

High lift trucks should be equipped with an overhead guard and a load backrest to provide protection to the operator from falling loads. Changes and modifications

All equipment changes are subject to the requirements of the Management of Change process. In addition, the manufacturer must approve any modifications or additions and any capacity, operation, maintenance instruction plates, tags or decals must be altered to reflect the modifications or additions. Classified area operations

Lift trucks operated in hazardous locations must be approved for such locations.



10.6.7 Inspection and Maintenance

General

The following general guidelines for inspection and maintenance shall be followed: • All forklifts will undergo a pre-use inspection by the operator. A

checklist for the pre-use inspection must be filled out and all discrepancies noted.

• The operator shall ensure that all defects noted are repaired before the forklift is put into service.

Scheduled maintenance should be performed in accordance with the manufacturer’s recommendations and documented. See Attachment 1 – Forklift Safety Checks on page 131.

10.6.8 Operation

General

General safe operating procedures include, but are not limited to, the following: • All forklifts must be maintained in good condition and be operated by

trained, competent, authorized operators, • Forklift operators shall protect themselves by using seatbelts where

provided and keeping all parts of their bodies inside the operator's compartment,

• Only the forklift operator is permitted to ride in the forklift. No passengers are allowed to ride in or on any part of the forklift,

• The operator shall maintain a proper lookout in the direction of travel and never reverse the forklift without first looking if visibility is limited, e.g. at a corner or a cross aisle, move slowly and sound the horn,

• Operators shall ensure that loads must be within the rated capacity as shown on the manufacturer's nameplate,

• Operators shall ensure that the loads are stable, well centred, and backed up against the carriage back plate,

• Operators shall ensure that the forklift travels with the forks raised only enough to clear the ground or other obstacles and with the mast vertical or tilted slightly back,

• Do not turn the forklift on an incline and shall avoid bumps, holes, or other uneven surfaces,

• Ensure that all operations are carried out in a smooth and controlled manner,

• The operator shall ensure that if the forklift is to be left unattended, it shall be made certain that it is not blocking an access way. Lower the carriage, place all controls in the neutral position, set the parking brake, and shut off the power. If the forklift is parked on an incline, or if some one is to be working on the vehicle, the wheels shall be blocked.

• Forklifts with internal combustion engines are to be operated only in well-ventilated areas where exhaust fumes cannot accumulate.

• Note: A forklift is to be considered “unattended” whenever the

operator is more than 25 feet way from the forklift or whenever it is out of the operator's view.



10.6.9 Safe travelling

General safe travelling procedures include, but are not limited to, the following: • All traffic regulations are to be observed, including authorized speed

limits. A safe distance is to be maintained, approximately three forklift lengths from the vehicle ahead, and the forklift is to be kept under control at all times,

• The right of way is to be yielded to ambulances, fire trucks, or other vehicles in emergency situations,

• Other vehicles travelling in the same direction at intersections, blind spots, or other dangerous locations shall not be passed,

• The driver of the forklift shall slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs the forward view, the operator shall travel with the load trailing,

• The operator is required to look in the direction of travel, • Grades shall be ascended or descended slowly. In order to prevent

the load from rolling or sliding off the forks, when travelling uphill, always lead with the load and when travelling downhill, always trail with the load,

• The forklift shall be operated under all travel conditions at a speed that will allow the operator to stop in a safe and controlled manner,

• Horseplay is not permitted, • The operator shall take extra care when driving on wet or slippery

surfaces, • Dock-board or bridge-plates shall be properly secured before they are

driven over. Dock-board or bridge-plates shall be driven over carefully and slowly and their rated capacity never exceeded,

• Running over loose objects on the roadway surface shall be avoided, • Speed shall be reduced to a safe level when negotiating turns.



10.6.10 Safe loading and safe lifting

The following general guidelines for safe loading and safe lifting shall be followed: • Before attempting any lift, it is most important to establish the weight

and dimension of the load. The dimensions are required to determine where the centre of gravity (CoG) will be in relation to the “load centre.” The weight should be checked against the capacity plate on the forklift to ensure that it has the capacity to lift the load,

• Forklifts should always be parked with the forks flat along the ground to reduce the trip hazard and to relax the load on masts with chain type hoists. Before moving, the operator must tilt back the mast and raise the forks to give clearance for forward or reverse travel. For stability, this clearance should be kept to a minimum as provided for by ground conditions,

• Adjust the clearance between the forks to the maximum to accommodate the load or to fit the fork pockets if fitted as follows:

Approach the load with the forks low and parallel to the ground and drive toward the load until it is almost against the back plate of the forks before stopping,

Raise the forks to take the load and tilt back in order to stabilize (retract the reach if necessary), and

Travel with the load as low as possible, ensuring the line of vision is not impaired,

While stacking loads, drive as close to the stack as possible and apply the brakes before raising the load,

Once raised, release brake and drive forward slowly until the load is above the stack,

Reapply the brakes, tilt forward until the mast is vertical, and lower the load on to the stack,

Reverse out slowly ensuring the load is stable and the forks are free,

Lower the forks completely before moving off, • Forklifts are often narrow for enhanced maneuverability and as a

result tend to be less stable laterally (side to side) and for this reason, with or without a load, never travel across an incline,

• Avoid using forks through sling eyes or to pick up pre-slung loads, especially when lifting on a single fork. Special hook attachments are available for this type of duty.

10.6.11 Charging and Fuelling Area Concerns

There are special considerations and concerns when involved in fuelling or recharging operations or when in these areas. These include, but are not limited to, the following: • Smoking is prohibited in fuelling or battery charging areas, • Precautions should be taken to prevent open flames, sparks, or

electrical arcs, • A properly charged and correctly rated fire extinguisher will be

provided, • Adequate ventilation should be provided and facilities available for

flushing and neutralizing any spilled electrolyte, • All mobile phones must be turned off, • All portable radios must be intrinsically safe and be approved for use

hazardous areas.



Attachment 1 – Forklift Safety Checks

FORKLIFT SAFETY CHECKS

VISUAL & OPERATIONAL CHECKS Comments MAST / CARRIAGE / CHAINS CHECK Comments

Fleet number & plate Hanger caps for wear & security

Check attachment number (s) Lift cylinder for leaks / security

Lever markings Tilt cylinder mountings wear / security

Safety labels fitted Forks for wear / distortion / cracks

Rating plate Forks latches

Ignition switch Carriage end stops fitted

Ignition light / charging Loadguard condition

Hour meter operational

Operation of all instruments AATTTTAACCHHMMEENNTTSS CCHHEECCKKSS

Stop cable where applicable AT 1

Lights / indicators AT2

Reverse bleeper Wear / security (inc. sideshifts)

Flashing beacon Wear pads / lubricate

Horn Mounting security

For/Rev neutral switch Cracks & distortion

For/Rev operational Cylinder for leaks

Inching / creep

Lift / lower fork BBRRAAKKEESS CCHHEECCKK

Attachment operational Park / brake on steepest slope

Hyd cylinder for leaks / scores Service brake operation

Security / fixing seat restraint Brake pipes for leaks & damages

Tyres / wheels for wear / damage

Tyres condition front ns CCHHAASSSSIISS && CCOOVVEERR CCHHEECCKKSS

Tyres condition front os Overhead guard condition

Tyres condition rear ns Seat unit condition

Tyres condition rear os Ballast weight security

General condition

SSTTEEEERRIINNGG CCHHEECCKKSS

Steering joints / links for wear EELLEECCTTRRIICCAALL IINNSSTTAALLLLAATTIIOONN

Steering unit for leaks & play Starter motor operation

Articulating bushes for wear Battery terminals clean / tight

Steer axle mounting for wear Security of battery & cables

Steering operation General condition of wiring

EENNGGIINNEE && TTRRAANNSSMMIISSSSIIOONN CCHHEECCKKSS

KKEEYY

Fuel system for leaks SATISFACTORY = SAT

Cooling system for leaks / hose condition

ADJUST = A

Visual condition of all belts REPAIR NEEDED = R

Ensure smooth running OBSERVATION = O

Oil Leaks NOT APPLICABLE = N/A Engineer Name: Signature: Date:



10.7 Personnel Lifting Devices

The purpose of this section is to protect the health, safety and welfare of employees by establishing minimum standards for the operation, inspection, testing, maintenance, and repair of personnel lifting devices. The two general categories of personnel lifting equipment covered in this chapter are: • Personnel Platforms & Personnel Transfer Devices. References: PCSB HSEMS 2.2-100-060 & Billy Pugh Company

Recommended Practise. General It is extremely hazardous for personnel to work from a crane-suspended personnel platform; therefore, personnel platforms should only be used, and approved to be used, after it has been determined there is no safer, practical, or more reasonable alternative to providing safe access for personnel to an elevated work site. Specifications Platform requirements Each personnel platform shall be equipped with a guard rail and should be enclosed at least from the toe board to the mid-rail with solid construction or expanded metal having openings no greater than 1/2 inch (1.27 cm). Platform deck shall have an anti-skid surface. Access gates, if installed, shall not swing outward during hoisting. Sliding or folding gates shall be equipped with a restraining device to prevent accidental opening. In addition to the use of hard hats, employees shall be protected by overhead protection on the personnel platform when they are exposed to falling objects. Enough headroom shall be provided which allows personnel to stand upright in the platform. The suspension system shall be designed to minimise tipping of the platform due to movement of personnel occupying the platform and should comply with all PCSB lifting gear regulations.



Other rigging requirements Other equipment used in personnel transfer will comply with the following: • When a wire rope bridle is used to connect the personnel rigging

platform to the load line, each bridle leg shall be connected to a master link or shackle in such a manner to ensure that the load is evenly divided among the bridle legs,

• Hook latches on load blocks and overhaul ball assemblies or other types of assemblies, shall be of a type that can be closed and locked. Alternatively, an safety pin bow shackle with a bolt, nut and retaining pin must be used,

• Wire rope, shackles, rings, master links and all other rigging hardware must be capable of supporting, without failure, at least 5 times the maximum intended load applied or transmitted to that component,

• Where rotation resistant rope is used, the slings shall be capable of supporting without failure, at least 10 times the maximum intended load,

• All eyes in wire rope slings shall be fabricated with thimbles, • Bridles and associated rigging for attaching the personnel platform to

the hoist line shall be used only for the platform and the necessary personnel, their tools and materials necessary to do the work,

• Personnel platforms shall not be used for any other purpose when not hoisting personnel.

Personnel Platform Inspection and Testing Pre-use testing requirements The following inspection and testing requirements are required to be conducted prior to carrying out any personnel lifting operations: • Visual Inspection - A visual inspection of the platform will be carried

out prior to each use. • Trial Lift - Upon successful completion of the Visual Inspection, a trial

lift with the unoccupied personnel platform loaded to at least the anticipated lift weight shall be made from ground level, or any other location where personnel will enter the platform to each location at which the personnel platform is to be hoisted and positioned. This trial lift shall be performed immediately prior to placing personnel on the platform. During the course of the Trial Lift, the Operator shall determine that:

all systems, controls and safety devices are activated and functioning properly,

that no interference exist, that all configurations necessary to reach those work locations will

allow the operator to remain under the 50% limit of the hoist’s/crane’s rated capacity.

Final and Balance Check - After the trial lift, and just prior to hoisting personnel, the platform shall be hoisted a few inches and checked to ensure that it is secure and properly balanced.



Six Month Examination An examination of the personnel platform shall be conducted every six months and shall include, but not necessarily be limited to, the following items: • Structural integrity of the platform, • Integrity of all fasteners, welds, and attachments, • Integrity of all slings, shackles, and associated rigging, • Antiskid surface not excessively worn. Annual Inspection An examination of the personnel platform shall be conducted annually and shall include, but not necessarily be limited to, the following items: • All items in the six-month inspection, • Proof Test - At each lift site, prior to hoisting personnel, the platform

and rigging shall be proof tested to 125% of the platform rated capacity. Holding the platform in a suspended position for 5 minutes with the test load evenly distributed on the platform shall carry out this proof test. After proof testing, a competent person shall inspect the platform and rigging. Any deficiencies found shall be corrected and another proof test carried out.

Mandatory minimums Personnel shall not be hoisted unless the following mandatory minimum conditions are determined to exist: • Hoist ropes shall be free of all defects, such as kinks, cuts, crushed or

broken wires, etc, • Multiple part lines shall not be twisted around each other, • The primary attachment for the lifting hook shall be centred over the

platform, • If the load line has been slack then the hoisting system shall be

inspected to ensure all ropes are still properly seated in sheaves and on drums.

Any defects found during inspections, which create a safety hazard, shall be corrected before hoisting personnel. Personnel Platform Operation Use and safety precautions Platform loading The following platform loading guidelines shall be complied with: • The personnel platform shall not be loaded in excess of its rated load

capacity, • The personnel platform shall only be used to carry the minimum

number of personnel, tools, equipment and material necessary to perform the intended work, it shall not be used to hoist any material or tools when not hoisting personnel,

• Materials and tools for use during a personnel lift shall be evenly distributed within the confines of the platform and secured.



Work practices The following general work practices shall be adhered to at all times during platform operations: • Before personnel exit or enter a hoisted platform that has not been

landed, the platform shall be secured to the structure where the work is to be performed, unless securing to the structure creates an unsafe situation,

• Personnel shall keep all parts of the body inside the platform during raising, lowering, and positioning,

• Tag lines shall be used unless their use creates an unsafe condition, • The crane operator shall remain at the controls at all times when the

engine is running and the platform is occupied, • The operator and all personnel working in suspended platforms must

understand and use API standard hand signals, • Personnel being hoisted shall remain in continuous sight of, and in

direct communication with, the operator or designated signal person. In those situations where direct visual contact with the operator is not possible, and the use of a signal person would create a greater hazard for the person,

• Except over water, personnel occupying the platform shall use an approved body belt/harness system with lanyard appropriately attached to the main/auxiliary block, or to a structural member within the personnel platform capable of supporting a fall impact for personnel using the anchorage,

• Over the water, personnel occupying the platform shall use an approved lifejacket or Personal Floatation Device and a workboat shall be provided and arranged for immediate launching.



Transfer during Darkness Transfer during the hours of darkness should be avoided if possible. However, if unavoidable, a transfer is permitted providing the operation is conducted consistent with the following minimum guidelines: • A JHA is carried out with all involved parties, • The transfer areas are adequately illuminated, • The operation must be conducted under the personal direction of the

Deck Foreman, • The potential for weather change during the personnel transfer

operation must always be recognized and the risk for personnel being stranded considered. In considering weather limitations, responsible personnel should take into consideration the probable effect of environmental factors on equipment and personnel involved in the transfer,

• The wave height and period must be within PCSB limitations, • The vessel must have the ability to hold station and heading, and

consideration must be given to the pitching and increase in vertical motion, as applicable, when holding,

• Consideration shall be given to crane hook control and boom tip motion,

• Consideration shall be given with respect to persons suffering from sea sickness and the practical difficulties of embarking to and/or debarking from a personnel basket when on a rolling and pitching deck,

• Consideration shall be given to the ability to accurately throw or otherwise deploy lines and/or personal lifesaving floatation devices,

• Consideration shall be given for the need of having safety lines in place when crossing exposed areas,

• Consideration shall be given to the fact that reduced visibility unavoidably results in an associated reduction in the ability to see potential risks,

• Consideration shall be given to the fact that in addition to reducing visibility, rain and significant sea conditions also can make decks and hand holds very slippery.



Cranes Operations from cranes shall comply with the following guidelines: • Hoisting of any personnel platforms shall be performed in a slow,

controlled, cautious manner with no sudden movements of the crane or derrick, or the platform,

• Load and boom hoist brakes, swing brakes, and locking devices such as pawls or dogs shall be engaged when the occupied personnel platform is a stationary position,

• The crane shall be uniformly level and located on firm footings. Those cranes with outriggers shall have them fully deployed following manufacturer’s specifications, as applicable, when hoisting personnel.

• Cranes with variable angle booms shall be equipped with a boom angle indicator, visible to the operator from his operating position,

• Pick and carry operations with a suspended personnel platform are prohibited,

• A positive acting device shall be used to prevent contact between the load block or overhaul ball and the boom tip (anti-two-block), or a system shall be used which de-activates the hoisting action before damage occurs in the event of a two blocking situation,

• The load line hoist drum shall have a system or device, other than the hoist brake, which regulates the lowering speed of the hoist (controlled load lowering),

• Free fall is prohibited. Personnel Transfer Device Equipment Selection General Due to the inherent risk involved in personnel transfer operations, extreme vigilance and care in the selection, inspection, maintenance, and operation of personnel transfer devices is required. Definition Personnel transfer is the movement of personnel from one installation, or vessel, to another vessel or installation by using a purpose built basket or carrier, lifted by an on-board crane. Selection PCSB facilities offshore use a "Billy Pugh" type personnel transfer device. A typical type used is the X-871, which has an overall length of 29 feet (stabilizer and load line extended) and incorporates a rough seas type net (similar to the standard X-870), but designed to operate in rougher seas. Design and construction The Billy Pugh X-871 personnel transfer devices are manufactured under the American Bureau of Shipping (ABS) equipment approval program for compliance with the requirements of API Specification 2C, 6th edition.



Specifications Platform requirements PCSB offshore facilities use a “Billy Pugh” Personnel Transfer Device, which meets the following minimum specifications (See Figure 1): • API Spec 2C 6th edition S.W.L 500 kg with a design factor of 10, • Lifting ring - 7/8" forged steel, • Has an overall length of 29 feet (stabilizer and load line extended), • Incorporates a rough seas type net, • Has hand spliced eyes (no swages), • Is equipped with a safety load line, • Has a stabilizer unit covered with plastic impregnated fabric, • Has ¾-inch netting lines of 9950 lbs test each, • Has a padded 30-inch top ring, • Has padded bottom ring with a 72-inch overall dimension, • Has shock absorbing padding and synthetic flotation material, • Is 9 feet from bottom to top ring, • Incorporates 5 chaffing pads at the bottom of the net, • Is of collapsible design for ease of storage, • Has a proven stabilising system. Personnel Transfer Device Inspection and Testing Pre-use inspection A pre-use inspection of the personnel lifting device will be conducted prior to each use and shall include, but not necessarily be limited to, a thorough visual examination. Monthly Inspection and Maintenance Each month the polypropylene rope will be reverse hand twisted so that the internal strands can be inspected for any signs of wear breakage, build up of dirt, grease or salt deposits. If any strand deterioration is noted, the basket will be replaced with a new unit. The bottom-padded ring will be inspected and checked for any sign of damage or tears. The main lifting ring shall be inspected and checked for any signs of wear or deformation. The net shall be fresh water washed after the inspection. Testing requirements Personnel baskets shall be tested every 12 months. The basket will be tested with a total test weight of 2.5 metric tonnes (MT) which will be hung from four equidistant points on the lower ring. The basket will be clearly marked with a fabric tag stating "MAX CAPACITY = 4 MEN". The identity tag attached to the lifting ring will state that the SWL = 500KG.



Figure 1

Personnel Transfer Device Operation Use and safety precautions Operations involving Personnel Transfer Devices shall be guided at all times by the following general use and safety precautions as well as being supported by a JHA: • Personnel riding on the "Billy Pugh" type of personnel transfer device

should first be instructed in its proper usage. Instructions should include, but not necessarily be limited to being instructed to stand on the outer rim at the rope openings, facing inwards, with arms crossed in front of their chests, holding the net roping firmly,

• No more than 4 persons (with light hand baggage) shall be allowed to ride the "Billy Pugh" at any one time,

• While waiting for the crane to hoist the personnel basket, it is advisable to keep one foot on the deck to stabilize the body,

• The "Billy Pugh" shall not be used to lift cargo, • The manufacturer, 'Billy Pugh Company', has never recommended tag

or guide lines to be attached to their devices. The reasons being that they can become easily fouled by wrapping themselves around objects on the deck or vessel. However, if a tag or guide line is required, 'Billy Pugh Company' has developed a system that incorporates horizontal wrapping on a urethane dipped polydac base rope. This tag line is much stiffer than a normal rope and resists fouling and has a much better gripping surface. Common lengths are 12 or 15 feet,

• Lifejackets, or other appropriate Personal Floatation Devices, safety helmets, and all other PCSB required PPE shall be worn by all personnel during transfer.



10.8 Securing of Loads

• All securing of loads is to be carried out by trained and competent

personnel, • Ensure that any lifting accessories used for securing the load are

compatible with the load, taking into account any attachment point on the load, the conditions in which the accessories will be used and their configuration of use.

• The preferred method for securing is by use of, but not limited to any of the following: a) Ratchet and straps, b) Bandit straps, c) Rigging equipment, d) Cargo netting etc.

• Ensure that appropriate measures are taken to prevent the load, or part of the load disintegrating while being lifted.

• Ropes, chains or slings should only be shortened in the correct and safe manner.

• Ensure that the lifting operation is organised so that the lifting equipment is not operated unless the person attaching and or detaching the load has given their authorisation to do so or it has been given by some other authorised person.

• Use of the term “Load Handler” will be used to describe the person with the responsibility for attaching/detaching and securing the loads to be lifted. This could be the operator of the lifting equipment or a slinger who would normally attach loads to a crane.

• The load handler should have the necessary competency to select suitable lifting accessories. Ensure that they received adequate information, instruction and practical experience on the principles of selection, use, care and maintenance of lifting accessories including any limitations of use.

• Further information on the training of rigger/load handler will be described on Section 11 – 11.5



10.9 Hydraulic Hoses

• All hydraulic hoses are to be free from damage on the outer rubber

hose as well as having corrosion free steel ends. • Where possible, the steel ends of the hoses when exposed to the

elements should be covered with denso tape or equivalent, to prevent corrosion.

• All stored hoses have a shelf life of 5 years if kept in a temperature controlled, dry environment and the ends are capped off.

• Any hoses that have not been stored this way should not be used and should be destroyed.

• All hoses shall be replaced after 5 years of service or as and when required as determined by inspection and/or deterioration.

• Each hose fitted to the crane will have a unique number which is dedicated to that hose. The information on this tag will have some but not limited to the following: a) Length of hose, b) End fitting types, c) Burst pressure (PSI) d) Safe working pressure (PSI), e) Test Pressure (PSI), f) Type and construction of hose used.

• This information shall be kept on a data base for each crane, so that spare hoses can easily be sought.

• The Data base will be kept by the platform, crane contractor and the hose manufacturer.

• All hoses will be sought through the Crane & Lifting Contractor as part of their contract.

Hydraulic hose failure costs and prevention Hydraulic hose has a finite service life, which can be reduced by a number of factors. From a maintenance perspective, little or no attention is usually paid to the hoses of a hydraulic system until a failure occurs. Hydraulic hose failures cost more than the replacement hose. Additional costs can include: • Clean up, disposal and replacement of lost hydraulic fluid. • Collateral damage to other components, e.g. a hose failure on

a hydrostatic transmission can result in loss of charge pressure and cavitation damage to the transmission pump and/or motor.

• Possible damage caused by the ingression of contaminants. • Machine downtime.



What causes hydraulic hose failures? Focus on the following points to extend hydraulic hose life and minimize the costs associated with hydraulic hose failures: • External damage Hydraulic hose failures are attributable to external physical damage through pulling, kinking, crushing or abrasion of the hose. Abrasion caused by hoses rubbing against each other or surrounding surfaces is the most common type of damage. To prevent external damage, ensure all clamps are kept secure, pay careful attention to routing whenever a replacement hose is installed and if necessary, apply inexpensive polyethylene spiral wrap to protect hydraulic hoses from abrasion. Multi-plane bending Bending a hydraulic hose in more than one plane results in twisting of its wire reinforcement. A twist of five degrees can reduce the service life of a high-pressure hydraulic hose by as much as 70% and a seven degree twist can result in a 90% reduction in service life. Multi-plane bending is usually the result of poor hose-assembly selection and/or routing but can also occur as a result of inadequate or unsecured clamping where the hose is subjected to machine or actuator movement. Operating conditions The operating conditions that a correctly installed hydraulic hose is subjected to will ultimately determine its service life. Extremes in temperature, e.g. high daytime operating temperatures and very cold conditions when the machine is standing at night, accelerate aging of the hose's rubber tube and cover.



10.10 Hydraulic Equipment & Parts

• Only trained, qualified and competent personnel are permitted to

maintain and adjust the hydraulic systems on the cranes or any other equipment.

• The hydraulic equipment on a crane are critical parts that ensures safe operations of the crane and therefore have to be well maintained.

• As part of the PPM schedule, pressures and operational checks are carried out as part of the condition monitoring to ensure correct operations of valves, pumps and motors etc.

• If any deviation in pressure is noted, then this will be reported to the Operation Supervisor, with the necessary action to be taken to ensure continued safe operations of the crane.

• If however the deviation is too much, i.e. pressure loss, then repairs will be carried out straight away, or the machine taken out of commission until new parts can be obtained. Only when the new parts are installed, the crane function tested and all operations are normal, will it be put back to normal service.

• All parts are to be sourced through the Crane & Lifting Contractor as part of their contract.

• Some cranes are of an age where, either the maker of the crane no longer exists or the parts are obsolete. If this is the case then re-design engineering needs to be done to obtain a new part that will meet the requirements and produce the same safe system of operation on the crane.

Warning! High pressure fluid is present in operational hydraulic systems. Fluids under high pressure are dangerous and can cause serious injury or death. Do not make modifications, repairs or adjustments to any hydraulic system unless you are competent or working under competent supervision. If in doubt consult a qualified technician or engineer.



Section 11 LEMS-11 Training & Certification 11.1 Assessor/Trainer Qualifications

Offshore Crane & Lifting Instructor/Assessor The Crane & Lifting Contractor shall provide a suitably qualified and experienced Instructor/Assessor to perform the services. Assessors/Instructors should be trained and accredited by a not-for–profit organisation. The objective here is to ensure that accreditations are bona fide proof of competence in the field of Offshore Pedestal Mounted Crane Driving. Example of an organisation offering assessor training and accreditation is the Australian Nationally recognised: • Training Accreditation Council of Western Australia. The instructor shall have as a minimum: a) A minimum of five (5) to ten (10) years hands on experience in crane

operations and/or maintenance in both open and closed loop hydraulic systems,

b) Should have received training by an API 2C Crane Manufacturer, c) Have experience in rig up/rig down and overhaul of API 2C Cranes on

offshore platforms, d) Be competent in the reading of load charts & schematic drawings, e) Be Qualified Forklift Instructor. f) Has met and sustained the requirements of a Qualified Offshore

Crane Operator for a minimum of 5 years experience in the operation and maintenance of offshore pedestal mounted cranes.

g) Holds current certification as a Trainer/Assessor recognized by PCSB. The above personnel shall: a) Be fluent in both written and spoken English, b) Be capable of reading and interpreting equipment drawings,

manufacturer’s maintenance manuals and load limit charts, c) Shall be fully familiar with standard crane signals, wire rope

limitations, types of slings and their colour codes, shackles, eye bolts, various lifting tackles and rigging equipment,

d) Shall perform the services in accordance with PCSB’s established safety procedures and practises.

Maintain good housekeeping at the work site, e) Shall be responsible for the proper use and care of tools and

equipment assigned to them and return all unused materials to stock, f) Be in sound physical condition and be capable of withstanding long

periods in inclement weather. Also be capable of climbing towers, vessels and structures.



11.2 Offshore Crane Operator

• Reference and guidance is applied in API-RP 2D Operation &

Maintenance of Offshore Cranes. • The Crane & Lifting Contractor as part of their contract with PCSB will

supply for each platform, Trained, Qualified and Competent offshore crane operators.

• The Crane & Lifting Contractor as part of their contract with PCSB will carry out the Training for all the offshore crane operators.

Key Requirements for a Qualified Offshore Crane Operator A person so designated by the employer who has appropriate offshore experience and training. Such appropriate experience and training must comprise minimum amounts of classroom sessions and hands-on field training, on offshore cranes specific to the type of crane to be operated by the qualifying operator. These minimum requirements are outlined in detail in 3.1.2 and Appendix A1, Commentary on Offshore Crane Operator Training of API RP 2D. The driver background is provided as an example of historical achievements required of offshore crane drivers. However, all drivers on PCSB platforms should be at a minimum Level 2 Qualified. Prior to employment all drivers on PCSB platforms would have achieved these levels of proficiency. There shall be at least two (2) levels of competency & proficiency for all offshore crane operators at PCSB Locations: 1. Level 1 offshore crane operators, 2. Level 2 offshore crane operators. The following is an offshore oil & gas industry wide standard issued as a guideline: Level 1 A Level 1 offshore crane operator is deemed to be a person who has met the following requirements: • Physical fitness, • A 60% to 80% pass in classroom training, • At least a 60% to 80% pass mark in hands on training, • Hands on training may only be taken after the appropriate classroom

training has been taken and the test passed. 150 hours of hands on training must be completed before a proficiency test is given. • Unsuccessful candidates will undergo a review before re-training, • Refresher courses will be carried out every 4 years, • Will not lift any load above 8MT, unsupervised, which is considered a

special lift or 50% of the SWL.



Level 2 A Level 2 offshore crane operator is deemed to be a person who has met and sustained the following requirements: • Physical fitness, • A 60% to 80% pass in classroom training, • 80% to 100% pass mark in hands on training, • Can operate a crane unsupervised and load will not exceed 100% of

the SWL of the particular crane. With this minimum training, qualifying operators should be qualified to safely operate the crane(s) on which they have been trained. With this minimum training, the qualifying operator should also be sufficiently qualified to perform the crane inspections outlined in 4.1.2 of API RP 2D, with the exception of the Initial, Quarterly and Annual Inspections. Operators will remain qualified to operate the cranes, provided they successfully complete the refresher training requirements outlined in 3.1.2d of API RP 2D. Trainee A trainee crane operator is deemed to be a person who has met the following requirements: • Physical fitness, • A 60% to 80% pass in classroom training, • Complete a satisfactory period (minimum 15 hours) of hands on

training under the guidance of the Instructor or until such time when the instructor certifies that the trainee can operate a crane satisfactorily.

Upon completion of the hands on training, the trainee can proceed to operate a platform crane subject to the following conditions: • Can only operate crane whilst a qualified crane operator is supervising

and present in the cabin, • Will not lift personnel on a personnel basket, • Will not lift any load with any safety system in bypass mode, • Will not lift any load which normally requires a lift permit, • Will not lift any load exceeding 20% SWL of the crane.

NOTE: All crane operators must have passed the Trainee Program before progressing onto Levels 1 & 2.

NOTE: All offshore crane operators must provide proof of operating and training history prior to employment and being permitted to operate offshore pedestal cranes.



Operator Qualifications Operators Offshore Cranes will only be operated by the following personnel: a. Qualified Operators who have met and passed the requirements, b. Trainees under the direct supervision of a Qualified Operator, c. Appropriate maintenance and supervisory personnel, when it is

necessary for them to do so in the performance of their duties, d. No other personnel, other than trained operators and

trainer/assessors should enter a crane operators cab. Qualifications for Operators Operators will meet the requirements of a Qualified Operator. Operators will meet the following physical qualifications: 1. Have vision of at least 20/30 Snellen in one eye and 20/50 in the other

with or without glasses, and have depth perception. 2. Must be able to distinguish red, green and yellow, regardless of

position of colors. 3. Have hearing, with or without a hearing aid, adequate for the specific

operation. 4. Have no history of a disabling medical condition which may be

sufficient reason for disqualification, e.g. epilepsy, heart disease, blackouts and recurring dizziness.

5. Must not suffer from fear of heights & must be in good physical condition and be able to withstand long periods in inclement weather conditions.

The following are recommended minimum requirements for operator training: Classroom sessions with written and hands on examinations on the types of crane to be operated by the qualifying operator. If an older mechanical (as opposed to non-mechanical) crane is to be operated, the necessary experience and training: a) Must be focused on this type of crane, b) Must be more intense than for non-mechanical cranes, due to the greater skill required to safely operate mechanical cranes. Such classroom sessions and examinations must cover all major crane components: the operational and maintenance procedures appropriate for the type and capacity of crane to be operated; and all major issues and guidelines addressed in this recommended practice, as well as in API Specification 2C, latest edition. The qualifying operator will demonstrate by written examination an appropriate understanding of the significant requirements of this recommended practice and API Specification 2C, latest edition.



Mandatory training will also cover lubricating points; adjustments, principles of crane operation, especially boom operating procedures; safety devices and anti-two blocking systems; the proper use and care of all running cables (wire and rope) and pendants; and the proper reading and understanding of crane lifting capacity and wire rope reeving charts, boom and indicator charts and hand signal charts. Further, the qualifying operator must attend a hands-on workshop on the proper inspection, use and maintenance of loose gear (slings, shackles, hooks, nylon slings, etc.) and be trained in all rigger requirements. Before a person can be designated a Qualified Operator: The person will also be required to demonstrate hands-on proficiency in the safe operation of cranes they are to operate. See C.3.1.2c of API RP 2D for suggested requirements on hands on proficiency. The employer will assure that operator qualifications are maintained, at a minimum every four (4) years, through appropriate refresher training. This will also include current vision and medical condition evaluations.

NOTE: The contractor who supplies the Crane Instructor/Assessor may be required to coordinate with the Department of Occupational and Safety and Health (DOSH) or any other regulatory body. If there is a need for their involvement, then PCSB shall assist as the need arises.



APPENDIX A1—COMMENTARY ON CRANE OPERATOR TRAINING

Many crane accidents or failures are the result of operational errors. These errors range from not checking control functions to overloading the crane. While no amount of training will prevent human error, training should be provided to minimize the occurrence of operational errors. API RP 2D Latest Edition, in defining the term Qualified Operator, references a formalized, written employer training program. An outline of the major items that could be included in this training program is listed following this paragraph. The program should also include a full review of the Latest API RP 2D document.

Training Outline a. Types of Cranes Used Offshore: 1. Mechanical cranes, 2. Non-mechanical cranes, 3. Electric powered cranes, 4. Other crane types. b. Crane Components and Lifting Capacities: 1. Components of a stationary mounted crane, 2. Boom Angle and Load Radius, reading a range diagram or load rating

chart, 3. Number of parts of line and relationship to rated load, 4. Limitations of the size and type of wire ropes used in boom hoist lines,

pendants and load hoist line, 5. Lifting capacity of the auxiliary hook, 6. Lifting capacity of load and boom hoist drums. c. Wire Rope Construction and Use: 1. Mechanics of wire rope, 2. Classes, designation and characteristics of wire rope, 3. Handling of wire rope, 4. Guidelines for replacement of wire rope, 5. Wire rope slings. d. Mounting Features of the Revolving Upper structure: 1. Hook rollers, 2. Ball ring, 3. King post. e. Boom Structure: 1. Types of boom construction (lattice, box, etc.), 2. Wire rope guides, 3. Boom bolts, 4. Pin connections. f. Limit Devices: 1. Boom-hoist limit, 2. Load hoist limits, 3. Boom stops, 4. All locking devices, 5. Anti-two block devices. g. Additional Items: 1. Sheaves. 2. Hand signals. 3. Control markings. 4. Engine emergency stop. 5. Gauges and indicators.



11.3 Signal Man/Banksman


Maintenance of Offshore Cranes & PCSB HSEMS 2.2-100-050. • The Crane & Lifting Contractor as part of their contract with PCSB will

supply for each platform, Trained, Qualified and Competent signal man/banksman.

Key Requirements for a Signal Man/Banksman A qualified Signal Man/Banksman is deemed to be a person who has met and sustained the following requirements: • Physical Fitness, • Classroom Training, • Hands on training, • Passed the training with a minimum pass mark of 60%. Responsibilities The Banksman is responsible for the following and if the banksman doubles as a rigger, then he must also complete the riggers responsibilities: • Ensure that he and the crane operator understand the signals, • If radio is used for communication, it needs to be tested, • The banksman must position himself so as to signal the crane

operator and see the load clearly, • The banksman must clear the area and the lift swing path of personnel

so that nobody will be jeopardized by having a load pass overhead, • He needs to make it clear to allow involved parties that he is in control

of the lift and the only person who will signal the crane operator. Standard Signals Signals between the crane operator and the designated signal person will be clear, audibly or visually, at all times. The Operator will not respond unless signals are clearly understood. Hand Signals Recommended standard hand signals are identified on Page 102. The use of these recommended standard hand signals is encouraged. Special Signals For operations not covered on Page 103, or for special conditions, additions or modifications to the recommended standard signals may be required. In such cases, these special signals will be agreed upon in advance by the Operator and the designated signal person and should not be in conflict with, or have the potential to be confused with, standard signals.



Instructions If it is desired to give instructions to the Operator other than those provided by the established signal system, the crane motion should be stopped. Signaling When operations are required to be controlled by signals, a designated signal person will be assigned to work with the crane. The designated signal person should: a. Be qualified by experience with the operations and knowledgeable of

the standard hand signals as shown on Page 102. b. Be in clear view of the Operator to ensure that their signals can be

seen. Their position should give them a clear view of the load, crane, personnel, and area of operation. If the Operator’s view of the primary signal person is obstructed, an additional signal person will be provided.

11.4 Crane Inspectors/Load Testers • Reference and guidance is applied in API-RP 2D Operation &

Maintenance of Offshore Cranes. • The Crane & Lifting Contractor as part of their contract with PCSB will

supply Trained, Qualified and Competent Crane Inspectors/Load Testers.

Qualified Inspector A person so designated by the employer who by reason of appropriate experience and training, in addition to meeting the requirements of a Qualified Operator, has attended formal training in and successfully completed courses on crane maintenance and troubleshooting (for non-mechanical and/or mechanical cranes, as applicable); on hoist troubleshooting and overhaul (non-mechanical or mechanical, as applicable); and on the structural aspects of offshore cranes, which give a knowledge of structurally critical components and critical inspection areas. With this minimum training, in addition to the Initial and Pre-use Inspections, the qualifying inspector should also be sufficiently qualified to perform the Initial, Quarterly, and Annual Inspections. The scope of these inspections is outlined in API RP 2D Latest Edition.



11.5 Rigger/Load Handler


Maintenance of Offshore Cranes & PCSB HSEMS 2.2-100-030. • The Crane & Lifting Contractor as part of their contract with the PCSB

will supply Trained, Qualified and Competent Riggers/Load Handlers. Responsibilities The Rigger who connects the slings to the container/load and to the crane is responsible for the following: • He must check the expiry date on the tag on the sling and reject the

sling if it is out of date, • He must check the load rating of the sling and ensure it is greater than

the load to be lifted, • He must visually inspect the slings and ensure they are free from any

defects such as: Kinks, Birdcages, Corrosion, Broken Strands, High Stranding, Core Protrusion.

• He must ensure a tag line is attached to the load and that the tag line is in good condition,

• He must understand the lift and have discussed it with the banksman and crane operator,

• When the slings are connected to the crane he must ensure they are free from twists and kinks and that the hook safety latch is working correctly,

• Once the lift has started he must control the load with the tag line. For larger loads more than one tag line is required.



Rigger Training An important part of crane safety is proper training of rigger personnel. Accidents and injuries can occur as a result of rigging errors. An outline of items that should be considered for a rigger training program is listed below: Training Outline A. Rigging Hardware: 1. Sheaves, Blocks. 2. Hooks, Safety latches. 3. Rings, Links, Swivels. 4. Shackles. 5. Turnbuckles. 6. Spreader and equalizer beams. 7. Cable Clips. 8. Pad eyes, eyebolts, other attachment points. B. Slings: 1. Sling configuration. 2. Sling angle. 3. Safe working limits. 4. Sling types (synthetic, wire, chain, etc.). 5. Cargo nets, baskets. C. Procedures and Precautions: 1. Load control/taglines. 2. Lift planning (load weight, center of gravity, etc.). 3. Inspection/rejection criteria. 4. Unbinding loads. 5. Personnel transfer. 6. Sling handling and storage. D. Rigging Basics: 1. Pinch points/body position. 2. Personal Protective Equipment (PPE). 3. Signals/communications. 4. Load stability.



Section 12 LEMS-12 Third Party Services 12.1 Overview

Introduction The purpose of this section is to discuss the needs for contracting supplies or services. Also the interface management, and contractor performance assessment and monitoring. The user is strongly advised to discuss all contract matters with PCSB Contracting Department in order to ensure that approaches and activities are consistent with the practices set out in the contract This chapter applies to all PCSB locations.

12.2 General Application There is a recognized need to have third party, or contractor services provided over a range of activities under PCSB authority. The success of the PCSB Lifting Equipment Management System depends, in part, on having documented processes and procedures and competent personnel trained in the procedures. Just as important, personnel with lifting expertise are essential to provide technical guidance, ensure proper application of appropriate standards and perform certification inspections and repairs. To this end, PCSB reserves the right to use and audit third party contractors who provide this expertise. Service types Examples of services that may be reasonably expected to be provided by a third party or contract personnel include: • Supply of rental cranes, • Supply of Offshore Crane Operators on a continuous basis (2 weeks

on – 2 weeks off), • Supply of Crane Certification/Inspectors on an "As Required" basis, • Continuous maintenance and/or inspection services, • Overhaul services for cranes and other lifting equipment, • Supply, repair and certification of Lifting Equipment (winches, wire

rope, etc), • Supply and repair of booms and other critical lifting equipment

components. • Supply a Crane Coordinator/Specialist, for the contract duration, to

manage all lifting, crane operations & maintenance issues between PCSB and the Contractor,

• Supply of Trainer/Assessors as and when required.



Provider types Providers will generally fall into one of three categories depending on the nature of the service delivered: • Equipment and personnel (including repair services and OEM parts

supply when unavailable in warehouse), • Equipment only, • Personnel Only. Equipment minimum standards All lifting equipment supplied by Third Parties or sub-contractors will, at minimum, meet the requirements of: • PCSB Lifting Equipment Management System (LEMS). • API Specification 2C, • API Recommended Practices 2D, • API Recommended Practice 9A (latest edition), • API Recommended Practice 8B (latest edition), • ASME B30.16 – Overhead Hoists • ASME B30.21 – Manually Lever Operated Hoists • ASME B30.9 - Slings • ASME B30.17 – Overhead Cranes • ASME B30.5 – Mobile Cranes • ASME B56.10 – Forklifts Service provider minimum standards All lifting services and personnel supplied by Third Parties or sub-contractors will, at minimum, meet the requirements of: • API Recommended Practice 2D, • ASME B30.5 - Mobile Cranes • ASME B30.50 – Forklifts • ASME B30.17 – Overhead Cranes



12.3 Evaluation

When the selection of a third party or contracted service provider is being considered, an evaluation is used to ensure qualified providers are selected based upon minimum acceptable service standards. These standards are as follows: • The potential lifting equipment suppliers shall be currently providing

this service in the industry and have the experience to manage and operate a company of this type, or provide proof of an existing partnership that is currently providing this service and currently operates and manages a company providing the same.

• Other requirements are as follows:

Provide proof of API Licence, Provide proof of established organization and professional profile

with resume/CV's of key staff, Safety performance and incident records for the past 3-5 years, Safety meetings and minutes, Program in place for recording incidents, near-misses, treatments,

etc., Programs in place for implementing safe working procedures at

new sites, Written and Management endorsed Alcohol and Drug Policies.

• Quality and Measurement system, including:

Examples of procedures from previous operations, Records of testing and verification programs conducted, to ensure

currency, Records of procurement of spare and replacement parts meeting

manufacturer’s specifications, Records and results of periodic audits and corrective and

preventative actions.

• Equipment inspection, testing, and maintenance programs, including: Performance criteria for each item of equipment, Service and test records, Test facilities, System in place for pre-acceptance inspection and/or testing to

ensure that equipment meets contract specifications, Log of maintenance and inspection programs, Records of third party validations, Schedule of future service, test, maintenance, and inspection

programs, System in place for ongoing monitoring to ensure that equipment

continues to meet contract specifications, Records of failures and the associated corrective or preventive

action.

• Training programs, certification, and competency verification for operators, riggers, and maintenance personnel, including:

Established criteria for selection and qualification of personnel, Procedures for validating qualifications and experience, Competency testing programs, Stable workforce, Drug and alcohol policy. Assessments of the general condition of the supplier’s equipment.



Responsibility Personnel from both PCSB and the Service Provider organization will be actively involved. General responsible parties are: • PCSB Management, • MSG Superintendent, • PCSB Contracting Personnel, • Crane & Lifting Contractor Management. Performance Requirements Introduction Clearly stated third party performance requirements and expectations are a fundamental necessity in successfully meeting the goals of the contracted scope of work in a safe and efficient manner. The requirements must be: • Clearly defined and communicated to the service provider’s

organization management, • Include a system for self-monitoring and stewardship. General Performance requirements will vary depending on the service provider, the depth and size of the contracted organization, the nature of the service provided and a number of other factors. Performance requirements will be determined by the MSG Superintendent, and at a minimum, give consideration to the following elements: • Adherence to Service Provider HSE programs, • Compliance to all applicable laws and regulations, • Incidents, near-misses, and associated follow-up actions, • Work practices and site conditions (including hazardous material

handling), • Adherence to Service Provider qualification, competency, and training

programs, • Conduct of emergency response drills, • Level of cooperation between PCSB and the Service Providers. Reporting Requirements When developing contract performance requirements, consideration shall be given to establishing a requirement for performance reporting, which may include written reports and/or verbal communication during the contract. Typically, written reports should be issued monthly; these could include descriptions of incidents and significant near misses and document the measurements in the monitoring plan and any actions taken.



Responsibility As the Contract Owner, it is the specific responsibility of the MSG Superintendent to: • Develop the contract specific performance requirements, in

consultation with the Service Provider, • Communicate the final performance requirements to PCSB Asset

Management, • Communicate the final performance requirements to the Service

Provider. Contract Owner Participation The MSG Superintendent in conjunction with the Platform Superintendent and Operations Supervisor, will contribute to, and participate in, the evaluation and selection of Third Parties or sub-contractors in all matters relative to lifting equipment, lifting services and/or lifting personnel. The MSG Superintendent bears the ultimately responsibility for the monitoring of Third Party performance relative to lifting equipment, lifting services and/or lifting personnel. Over the course of the contract, the MSG Superintendent will provide the Platform Superintendent and Operations Supervisor with information concerning third party performance. Operations Supervisor Participation The Operations Supervisor is responsible for monitoring and reporting to the PTS and/or MSG Superintendent, of Third Party or sub-contractor equipment, services and personnel as follows: • Equipment: Immediately after commissioning, monthly for the next

three months, • Services: At the completion of the first task, monthly for the next

three months, • Personnel: At the completion of the first trip, monthly for the next

three months. Feedback The MSG Superintendent will provide to PCSB, a review of the relevant performances of Third Parties in a timely manner after reviewing the reports from the relevant Operations Supervisor, and will further recommend continuance or discontinuance as appropriate. Contractor Monitoring Overview Contractor monitoring, by both contractor staff and PCSB personnel assigned to oversee the responsibilities for contractor performance, plays a critical part.



Section 13 LEMS-13 Risk Assessments Introduction This section contains a general discussion of Job Hazard Analysis (JHA), associated JHA procedures, and deck management issues. The contents of this section apply to all PCSB locations.

13.1 Job Hazard Analysis

Purpose The purpose of this section is to establish the requirement that a Job Safety Analysis (JHA) be conducted for all lifting tasks using cranes and/or other powered and or manual lifting equipment. Objective The objective of the JHA requirement is: • To document each lifting activity in sequential steps, identify hazards,

and recommend precautionary actions to control and/or eliminate the hazards, and to provide personnel protection while working near or at the lifting equipment area.

• To perform periodic audits to assess procedure inadequacy, performance compliance, and coach the employees and contractors on safe work practices.

Application This procedure applies to all PCSB locations/ facilities and shall be complied with by all PCSB employees and contractor personnel. General Requirements Every lifting task must have a JHA in place prior to commencement of that specific lift/task. All crane operations must have a lift permit along with the JHA. Lifting tasks which are deemed as ‘Routine’ (Routine is defined as any work/lift activity which is usually performed for the normal operation and maintenance of a facility) and which does not have the high potential for personnel injury, environmental incident or any other hazards, only require a generic JHA. A generic JHA is a safety analysis document that has already been established for that same specific lifting task and all lifting, operating and safety related criteria remain unchanged. Non-Routine tasks, (a non-routine task is defined as any work/lift activity which is uncommon for the normal operation and maintenance of a facility), will require a JHA before that specific lifting work/task is carried out.



Definitions The following definitions apply throughout: Operations JHA: For work carried out by Operations personnel in their

own work area, such as operating or isolating of operating systems, equipment, vessels and/or lines.

Facility JHA: For work carried out by Maintenance/Technical

Departments or Contractors within their own work area. Special JHA: For work carried out by Maintenance/Technical

Departments or Contractors inside Operations areas. Mandatory JHA: For work to be carried out as stated below. Note: It is mandatory to have a JHA in place prior to issuing work

permits for the following work: • Lifts equal to or greater than 8te in conjunction with a Lift Permit, • Lifting tasks involving work on lines/vessels/equipment, which will

create a hazardous environment, • Removal an Installation of wellhead gratings, • Wind speed exceeding 30 knots, • Visibility less than 30 meters, • Sea Swell exceeding 2.5 meters, • Multiple crane lift, • Failure to fully illuminate the load or load path, • Greater than a four legged lift, • Lifting tasks on systems connected to flares, • Blind lifts, • Lifting tasks involving work in confined spaces (including lines greater

than 25 cm diameter and/or 2 meters below the shell rim on the deck of a floating tank roof),

• Any lifting work involving contact with hazardous chemicals/materials, • Any lifting operation where welding and/or hot tapping work on live

systems is carried out. When completed, each JHA will be attached to the corresponding work permit and discussed, reviewed and filed. Responsibilities Overview The department concerned shall be responsible for developing the JHA for work/lift activities carried out by its own personnel within its own areas, as defined by Operations and/or Facility JHA. Work/Lift activities as defined by Special JHA being carried out outside its own work areas shall be prepared by the department performing the task and verified by the Supervisor of that work area. For all Mandatory JHA’s, Operations Department shall compile the JHA with the assistance from the personnel involved. For work/lift activities (other than those covered in Mandatory JHA) involving more than one Department, the JHA shall be compiled by the department in charge of the task/lift, even though the discussion maybe led by another department.



Position Responsibilities Person In Charge of Facility Heads of Operations are accountable for the successful implementation of the JHA process through their subordinates. Platform Superintendents Platform Superintendents are responsible: • For ensuring this process is carried out within their work area, • For interfacing with other departments, including contractors, to form a

inter company group when the work activities require the formulation of a JHA,

• For approving new and updated JHA’s within their work group, • Shall include the following in their annual objective (goals):

The number of approved JHA’s to be reviewed, The number of JHA audits to be conducted annually To appoint the work group to do the JHA on the approved JHA, To ensure all JHA and JHA Audit reports are properly documented

and filed for reference and verification.

Operation Supervisors and Engineers Operation supervisors and engineers are responsible: • To identify, review, update and maintain proper document control for

all approved JHA’s and JHA Audit reports for the departments, • To participate and assign personnel who are conversant with the job

details to form work group to draft the JHA as required, • To review the proposed or updated JHA for the final submission to the

Platform Superintendent for approval, • To participate in the JHA inter company group discussions as

assigned, • To coach the employees on the method of doing the JHA and proper

document control, • To participate and/or assign his charge to perform a JHA Audit, • To disseminate approved JHA and JHA Audit reports to their

subordinates. Crane Operator, Banksman/Rigger and Other Users It is the responsibility of the employee to: • Ensure the job activities and practices are carried out in a manner as

set out in the approved JHA, • Analyze and prepare the draft JHA, • Update the JHA and the JHA audit as required, • Submit the draft and updated JHA to the Supervisor for review, • Stop work/lift activities and review JHA with the Supervisor and/or

work group when employees and/or contract personnel anticipate any hazard during the course of the work/lift,

• Participate in work group activities on the JHA and the JHA audit.



Contract supervisors Contract Supervisors are responsible for the following: • The proper conduct of work/lift activities in accordance to the work

steps stated in the approved JHA, • Working with the appropriate PCSB representative to get approval of

the JHA and distribute such information to their employees during the toolbox meeting before the work/lift commences,

• Participating in the JHA review as and when called upon to do so by an PCSB representative,

• In ensuring that all their employees and subcontractors are familiar with the approved JHA steps and abide by them,

• In ensuring that work/lift activities are stopped as and when any hazards or risks are encountered,

• Seeking PCSB representative concurrence to re-start work/lift only after the approval JHA is reviewed.

All personnel A JHA Meeting Checklist will be prepared by the relevant personnel and/or teams who will be performing the task/lift. If this work involves the use of a crane, the crane operator shall play a key role in the JHA development. JHA Procedures Introduction A Job Hazard Analysis involves four basic steps: • Select a job to be analyzed, • Separate the job into its basic steps, • Identify the hazards associated with each step, • Identify methods to control each hazard. After a job/task has been selected and the JHA has been initiated, a form is prepared; listing the basic job/task steps, the corresponding hazards, and the safe procedures for each step.



Process The JHA form has 4 columns for subordinate tasks as follows: • Task Description:

Breakdown the job/task into successive steps. Describe what is done and list the steps in natural order.

• Safety, Environmental and Potential hazards:

Identify all hazards by relating to each basic step, listing down the potential hazards affecting personnel safety and efficiency.

• Control/Recovery Measures:

Develop ways to control/eliminate hazards and/or potential accidents by finding a better and safer way of doing the job/task such as:

Proposing safety measures to overcome the potential hazards Reducing job/task steps Reducing frequency of doing the job/task.

Results of JHA:

Has the task been made safe, Can the task be carried out safely

• In each step, an analysis will be made of the potential hazards or

hazardous conditions and associated risks at that work site, which could lead to any PCSB or Contractor’s exposure to any potential harm.

• A hazard is defined as something that has the potential to cause harm.

Hazards When conducting JHA, process participants should be mindful to include, but not be limited to, the following considerations: • Housekeeping, • Poor work practices and procedures, • Repair, construction or maintenance work, • Impact of third party incidents, • Acute or chronic exposure to hazardous materials, • Releases or spills, • Human factors such as lighting levels, noise, access, etc., • Corrosion and/or fatigue, • Worn or poorly maintained equipment, • Environmental factors such as wind, rain, thunderstorms, sea

conditions, • Simultaneous Operations (SIMOPS) JHA review It is required that a JHA is updated after each review or audit is carried out. The update should include any steps or potential hazards not listed originally, but subsequently identified during the job/task. This will ensure that all personnel who undertake the task/job in the future are aware of all potential hazards and risks that were identified.



JHA Audit A planned JHA Audit shall be used and the Audit shall be conducted through observation of the respective lifting activities. The Audit shall consist of the following steps: • The work group as appointed by the Platform Superintendent shall

select the approved JHA to be audited, • The work group shall identify who is to be audited, • The Audit will be conducted in order to:

observe and compare performance against the approved JHA, to evaluate the effectiveness of the safe work practices as carried

out by the personnel and check for non-compliance, to record observations, to review observations with whom JHA Audit was conducted,

• Supervisor shall conduct discussion of the JHA Audit findings with relevant personnel during the toolbox meeting,

• Final JHA Audit reports shall be submitted to the Platform Superintendent for follow up and filing.

Document control The document control process shall be consistent with the following guidelines: • Numbering of approved JHA and JHA Audit shall be on area basis, • Completed JHA shall be attached to corresponding work permits (if

applicable), and discussed at toolbox meetings, • The respective Operation Supervisors shall set up a filing system such

that all JHA’s are accessible by all respective employees, e.g. Supervisors Office,

• A Master Copy shall be kept at a designated place, i.e. in the office of the Approving Authority, and for a specific time period.

Training PCSB employee’s and contract personnel receiving training shall demonstrate an appropriate level of proficiency and competency with regards to knowledge and skills relevant to this approved work practice. Procedural review The Lifting Job Hazard Analysis will be reviewed under the following scenarios: • Incidents that occurred due to the failure of the system, • Periodic Field Auditing to ensure:

that the procedure is being properly implemented and used, that personnel are being protected from hazards relative to the

scope of tasks/jobs covered, that the procedure is current and applicable to the organization

and operation.



13.2 Deck Management

Purpose The purpose of this section is to ensure that a proactive approach is established and sustained with regards to deck management in order to eliminate adverse lifting incidents. Key requirements Key requirements in deck management and planning include, but are not limited to, the following: • No-load and restricted areas are to be clearly marked and

communicated, • There are to be no loads in no-load areas, • Loads in restricted areas are controlled, • Access ways are kept clear at all times, • Escape routes are established, marked, and kept clear at all times, • Lift plans are drawn up and discussed at meetings, • Unusual lift plans require a dedicated planning meeting. No-load areas Responsibilities for no-load areas are as follows: • The Operation Supervisor and or Deck Foreman is responsible for

ensuring that all no-load areas are: properly identified, painted with black and yellow stripes, clearly marked and communicated to all personnel,

• The Crane Operator or Deck Foreman is responsible for ensuring that no-load areas are kept free of all loads.

Restricted load areas Responsibilities for restricted load areas are as follows: • The Operation Supervisor and or Deck Foreman is responsible for

ensuring that all restricted load areas are: properly identified, painted with red and white stripes, clearly marked and communicated to all personnel,

• The Crane Operator or Deck Foreman is responsible for ensuring that excessive weight loads are not placed in restrictive areas.

Equipment placement Responsibilities for equipment placement are as follows: • The Operation Supervisor and or Deck Foreman are responsible for

ensuring that all equipment placed on the decks is arranged effectively and safely such that walkways and escape routes are neither blocked or restricted.



Access ways Responsibilities for access ways are as follows: • All personnel are responsible for ensuring that access ways are kept

free of obstructions at all times, • The Operation Supervisor and or Deck Foreman on site will inspect all

access ways for obstructions on a daily basis, • The Crane Operator or the Deck Foreman on site is responsible for

ensuring that any access way obstructions are removed in a timely manner.

Escape routes Responsibilities for escape routes are as follows: • The Operation Supervisor and or Deck Foreman is responsible for

ensuring that all escape routes from all parts of the work area are identified, clearly marked, and communicated to all personnel,

• All personnel are responsible for ensuring that escape routes are kept free of obstructions at all times,

• The Operation Supervisor and or Deck Foreman on site will inspect all escape routes for obstructions,

• The Crane Operator or the Deck Foreman on site is responsible for ensuring that any obstructions to escape routes are removed in a timely manner.

Short term planning Responsibilities for short term planning are as follows: • The Deck Foreman is responsible for ensuring that the planned lifting

activities are discussed at the daily morning meeting, • The Crane Operator is responsible for communicating the work plan

for all lifts to the meeting attendees. The work plan for all lifts will feature, but not necessarily be limited to, the following:

Job Hazard Analysis, Non-routine Lifts, Personnel Lifts, Critical Lifts, Obstructed View Lifts, Severe Weather conditions.

Long term planning Responsibilities for long term planning are as follows: • The Operation Supervisor and or Deck Foreman is responsible for

ensuring that the plans for non-routine lift activities are formulated at a dedicated meeting with all involved personnel.

• These plans will address, but not be limited to, the following: Production impact, e.g. production shutdown for lifting operations, Resource and Availability, e.g. personnel, special equipment, etc., Simultaneous Operations, e.g. diving, drilling, wireline, etc., Design and Planning, Supervision of Lift Operations, e.g. unusual lifts, The Lift(s), ensuring the task passes without incident.



Section 14 LEMS-14 Incident Investigation 14.1 Lifting/Dropped Object Investigation

Purpose The purpose of this section is to reduce and to eliminate the number of incidents/accidents and near misses associated with lifting activities in and around all PCSB Locations. Note: All lifting operations must, before they are carried out, have

and be accompanied by a current JHA. Lifting operations must only be carried out by qualified, trained and competent personnel. Lifting incidents All crane/lifting incidents and near misses will be treated in the same manner as any other accident/incident with regards to the reporting procedure. These will be reported instantly to the PTS and all relative parties. See Attachment 1 – Example of an Incident Report All incidents will be reported on the appropriated PCSB form and will be submitted to the Platform Superintendent and Operations Supervisor. These will then be passed onto the PTS for review and corrective action. See Attachment 2 – Example of a Corrective Action Report. If the supply vessel is involved in the incident, then the Captain of the vessel shall report the same incident to the PCSB Marine Superintendent. A witness statement from any involved parties can also be submitted as back up to the incident report. See Attachment 3 – Example of a Witness Statement Record. An investigation team may be set up at the discretion of the PTS, to travel offshore or to the location of the incident, to carry out further investigations. Unsafe lifts Any load that is considered unsafe for lifting shall be returned to the source or origin. A hazard report will be raised and circulated to the appropriate departments. Similar controls are applied for back-loading operations.



Responsibilities Each location is required to report to their PTS all Incidents, including occurrences of dropped objects, and Significant Near Misses involving any item of lifting equipment or any event that occurs during the course of any lifting operation. Note: As with all incidents and accidents, lessons cannot be learned unless the outcome of any investigation and corrective actions identified, are distributed to interested parties. Cooperation and the free flow of knowledge and experience cannot be viewed with suspicion or apprehension.

Attachment 1 – Example of an Incident Report

INCIDENT REPORT Report No.:

1-Details of Incident: Note: Include all weights and what type of failure occurred. Originator:

Position:

Date:

2-Personnel Involved: Names:

Position:

3-Damged Caused: Signed:

Position:

Date:

4-Injury to Personnel/Property:

5-Further Actions:

Signed:

Position:

Date:



Attachment 2 – Example of a Corrective Action Report

CORRECTIVE ACTION REPORT Report No:

1-Details of Deficiency/Problem: Originator:

Position:

Date:

2-Request for Corrective Action: Action Party:

Position:

Proposals for corrective action in respect of the situation described at (1) above are requested. Signed:

Position:

Date:

3-Proposed Corrective Action: Signed:

Position:

Date:

4-Agreement & Timescale: It is agreed that the proposed corrective action is appropriate and will be completed by (date): ** Signed: Action Party

Position:

Date:

Signed: *Auditor/Q.A. Representative

Position:

Date:

5-Record of Close Out: The above corrective action has been completed to my satisfaction. Signed: *Auditor/Q.A. Representative

Position:

Date:

6-Proposed Preventive Action: Signed:

Position:

Date:

* Delete as applicable ** Revised completion date :....................................................( if any)



Attachment 3 – Example of a Witness Statement Record

WITNESS STATEMENT RECORD Incident Date: Incident Ref: (HSEQ Manager) Witness Name: Incident Location:

Statement:

Witness Signature:

Date:



Section 15 LEMS-15 Emergency Procedures 15.1 Procedures

All emergency procedures must, before they are executed, be accompanied by a JHA and be carried out by qualified, competent, trained personnel. In an emergency, all work must be stopped, the worksite made safe and all equipment shut down. All personnel not directly involved in the emergency or part of the emergency response team should listen out for PA announcements and proceed to their muster stations as directed. All PCSB Emergency Procedures will be followed at all times during an emergency as well as those set down by the equipment manufacturers when appropriate. If emergency load lowering of the crane winch is being carried out, this must be under the supervision or be carried out by a qualified, trained and competent person. This applies to all types of lifting equipment. Failure to comply with this instruction could lead to serious damage to equipment, property and or personnel.

15.2 Emergency Response

Emergencies/Incidents Investigating and reporting on any incident is the responsibility of the Management of the department in control of the personnel, operations or equipment involved. Responsibility for investigating and reporting is NOT DEPENDENT on any attachment of BLAME. Where complex situations occur, the ‘sphere of influence’ of the line organisations shall generally be considered thus: • Where injuries occur, line supervision of the injured person or persons

shall report, irrespective of the location of the incident or equipment involved.

• Where no injuries occur, line supervision responsible for the assets, equipment or area involved shall report.

Possible options available to the Platform Superintendent and or Operations Supervisor when informed are to: • Arrange for an on-site safety supervisor to take a key role in the

investigation. • Arrange for a supervisor or group of local supervisors to investigate

the incident.



15.2 Emergencies/Incidents – Continued

• Appoint a formal investigation team led by a member of Management,

either local or from another location. • Take immediate steps to inform Senior Management through the

emergency reporting system so that a decision may be taken to mount a serious major incident investigation.

Where an incident is serious, and specialist technical investigatory assistance may be required, the Platform Superintendent should liaise with the PTS to discuss the most suitable course of action. Where practicable, the PTS should assist in the conduct of incident investigations. It should be borne in mind that the Company may have a responsibility to report the incident to the appropriate Government Inspectorate, and the decision on the most suitable steps to take in the circumstances shall be taken by the PTS. Where multiple casualties occur or persons become injured as a result of a serious asset or equipment failure, the senior line supervisor should decide the most appropriate line organisation to take the lead in conjunction with the Platform Superintendent. Where incidents of major significance occur, Senior Management and/or the PTS may appoint or arrange the appointment of a special investigation team. The role of the PTS with respect to incidents is, wherever possible, to provide active support and guidance to line departments, during both investigation and follow-up. Incidents will normally be reported by the immediate line supervisor in whose ‘Sphere of Influence’ the incident occurs. Where appropriate, they will obtain assistance from safety personnel. They should not report accidents or injuries to themselves unless they are the most senior supervisor on that site or location shall not report. They should identify or attempt to identify the seriousness or potential for escalation of the incident involved so that they may:

• Report immediately to a more senior level, • Investigate or arrange an investigation to be reported on the

appropriate form, • Having determined that the incident is of ‘Minor Significance’ report

brief details on the appropriate form, for transmittal to Head Office.

Whatever decisions are adopted the line supervisor should always ensure that appropriate installation or site supervision are informed as soon as possible of any incidents either directly or through safety staff where these are in position.



15.3 Emergency Response Plans

PCSB has emergency response procedures in place. Such procedures and plans are documented, tested, regularly reviewed and updated as necessary.

Accident/Incident Reporting

Fortunately, PCSB has yet to encounter a full emergency situation but the current procedures in place will cope adequately with any emergency arising.

In general terms the following summarised procedure applies: • All accidents/incidents or near misses no matter how trivial are to be

reported. • In the event of an incident occurring either involving the cranes or any

lifting equipment, both client and contractor incident report forms will be completed.

• The contractor and client shall carry out independent thorough investigations into the incident. All details found during the investigation and conclusions drawn shall be fully shared at the end of the investigative process.

Emergencies In the event of an emergency onboard, the platform’s own Emergency Response procedure will be put into force as directed by the Platform Superintendent. In the event of an emergency scenario occurring, the Crane & Lifting Contractors personnel department will act as the main focal point for their staff. As such in the event of a major incident, the human resources and training department shall be contacted first. In the event of there being difficulties raising the personnel department, the contract manager and lastly a director of the company shall be contacted. Upon initial contact with the Crane & Lifting Contractor, their own emergency response system shall come into play. However, no information shall at any time be passed on by the contractor to either the press or family members unless client’s instruction to proceed has been received. All contract personnel on the platform will take part in the installation's emergency response exercise and training programme.

SAFETY IS EVERYONES BUSINESS

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