BP-CDZZZZ-CM-PRO-5001 - C2

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UNCONTROLLED WHEN PRINTED

TECHNICAL DOCUMENTATION FRONT SHEET

EXPLORATION (SHAH DENIZ) LTD AND

AZERBAIJAN INTERNATIONAL OPERATING COMPANY

Az Developments

Lifting Equipment Control and Operational Procedures

C2 16/11/11 For Project Use BR JM NP

C1 09/03/09 For Project Use BR JM MJ

A1 15/10/08 For Review BR JM MJ

Rev Date Reason for Issue Prepared Checked Approved Prepared Reviewed Approved

Disc. Eng.

Disc. Lead

Contr. Rep Author Disc SPA

AIOC/

Category Code Description

Location Code CD Common

Document Type PRO Procedure

System Number 00 General

Notes:

Company Location Code Disc Doc.

Type Sequence

No. Rev. This document shall not be reproduced without permission of AIOC and Exploration Ltd

CDZZZZ CM PRO 5001 C2

LIFTING EQUIPMENT CONTROL AND OPERATION PROCEDURE BP-CDZZZZ-CM-PRO-5001 Az Developments

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Revision History and Hold Record

The Revision History section describes changes or updates to the document. A history of changes serves as a reference for the reader to understand any changes made to the document. A list of document changes is required for audit purposes.

Revision History

Date Rev. No. Detailed Description of Change Ref.

Section

10/11/11 C2 Section update to make reference to the golden rules and be more specific about the sites that this document will apply to 1.1

10/11/11 C2 PUWER added to abbreviations list 1.6 10/11/11 C2 Rigging superintendent section updated – writing of plans 2.2.3 10/11/11 C2 Banksman section updated 2.2.6 10/11/11 C2 Rigger section updated 2.2.8 11/11/11 C2 Competency section updated for new positions ( Banksman, Overhead

Crane Operators, Rigging Loft keeper, MEWP’s and Hiab’s) and new more detailed definition of training requirements

2.4

12/11/11 C2 New section added on Hands Free Lifting 2.7 12/11/11 C2 New section added on Lifting Over Live Plant 2.9 12/11/11 C2 New section added on Ground Loadings 2.10 13/11/11 C2 Tandem Lifts with BDWJF cranes at 80% not 100% 2.11 13/11/11 C2 Updated Section on Supply of cranes “up to 8 years old” 3.5 13/11/11 C2 New section added on Containers 3.9 13/11/11 C2 Change in wording and addition of new standard EN14502-1 3.10.1 13/11/11 C2 Updated Section on MEWP’s “up to 8 years old” and Type 3.11 13/11/11 C2 New section on control of webbing slings 4.8.4

Hold Record Hold Ref. Description / Reason for Hold Ref.

Section


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Table of Contents 1 GENERAL .............................................................................................................................................. 5

1.1 INTRODUCTION.................................................................................................................................. 5 1.2 PURPOSE ......................................................................................................................................... 6 1.3 SCOPE ............................................................................................................................................. 6 1.4 REFERENCES.................................................................................................................................... 7 1.5 DEFINITIONS ..................................................................................................................................... 7 1.6 ABBREVIATIONS ................................................................................................................................ 8

2 SECTION “A”......................................................................................................................................... 8 2.1 ACTIVITIES – CONTROLLING PROCEDURES........................................................................................... 8

2.1.1 Equipment ............................................................................................................................... 8 2.1.2 People ..................................................................................................................................... 9

2.2 ROLES AND RESPONSIBILITIES............................................................................................................ 9 2.2.1 Site Manager ........................................................................................................................... 9 2.2.2 Maintenance Supervisor.......................................................................................................... 9 2.2.3 Lifting Superintendent ............................................................................................................. 9 2.2.4 Foreman / Supervisor ............................................................................................................ 10 2.2.5 Crane Operators (Mobile, Crawler and overhead) ................................................................. 10 2.2.6 Banksman / Signal Person / Basic Slinger............................................................................. 11 2.2.7 Riggers.................................................................................................................................. 11

2.3 THIRD PARTY RESPONSIBILITIES (SUB CONTRACTORS) ...................................................................... 12 2.4 TRAINING AND COMPETENCE............................................................................................................ 13

2.4.1 Crane Operators.................................................................................................................... 13 2.4.2 Forklift Truck Operators......................................................................................................... 14 2.4.3 Banksman / Signal Person / Basic Slinger............................................................................. 14 2.4.4 Riggers.................................................................................................................................. 14 2.4.5 Lifting Operations – Internal Competence Standard .............................................................. 15 2.4.6 Overhead crane operators..................................................................................................... 17 2.4.7 Rigging Loft Keepers............................................................................................................. 17 2.4.8 MEWP’s (Mobile Elevated Work Platform) ............................................................................ 17 2.4.9 HIAB’s ................................................................................................................................... 17

2.5 COMPLETING THE STANDARDS ......................................................................................................... 17 STANDARD LEVELS...................................................................................................................................... 18 2.6 ASSESSMENT STANDARDS ............................................................................................................... 19 2.7 HANDS FREE LIFTING....................................................................................................................... 19 2.8 PLANNING OF LIFTING OPERATIONS................................................................................................... 19

2.8.1 General Planning................................................................................................................... 20 2.8.2 Heavy Lifts ............................................................................................................................ 20

2.9 LIFTING OVER LIVE PLANT ............................................................................................................... 22 2.10 GROUND CONDITION AND LOADINGS................................................................................................. 23 2.11 PROVISION OF SOCAR HC CRAWLER CRANES ................................................................................. 23 2.12 CRANE CERTIFICATION .................................................................................................................... 23 2.13 MAINTENANCE AND CERTIFICATION................................................................................................... 24 2.14 OVERHAUL AND INSPECTION............................................................................................................. 24 2.15 CONTROL OF RIGGING EQUIPMENT ................................................................................................... 26 2.16 THIRD PARTY INSPECTION................................................................................................................ 26 2.17 LIFTING OPERATIONS AUDITS ........................................................................................................... 27

2.17.1 Audits .................................................................................................................................... 28 2.17.2 Monitoring ............................................................................................................................. 28 2.17.3 Audit Findings........................................................................................................................ 28 2.17.4 Follow up Audits .................................................................................................................... 28

3 SECTION “B”....................................................................................................................................... 28 3.1 INTRODUCTION................................................................................................................................ 28 3.2 SCOPE ........................................................................................................................................... 29 3.3 DESIGN NOTES ............................................................................................................................... 29 3.4 GLOSSARY OF TERMS...................................................................................................................... 30


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3.5 CRAWLER AND MOBILE CRANES ....................................................................................................... 34 3.6 OVERHEAD CRANES ........................................................................................................................ 35 3.7 SPREADER BEAMS AND LIFTING FRAMES........................................................................................... 36 3.8 LIFTING POINTS............................................................................................................................... 37 3.9 CONTAINERS................................................................................................................................... 38 3.10 MAN RIDING BASKETS ..................................................................................................................... 39

3.10.1 Man Basket Construction ...................................................................................................... 39 3.10.2 Man Riding Belts and Harnesses .......................................................................................... 41 3.10.3 Forklift Cages / integrated Working platforms........................................................................ 41

3.11 CHERRY PICKERS (MEWP’S)........................................................................................................... 42 3.12 GROMMETS AND CABLE LAID SLINGS ................................................................................................ 43

4 SECTION “C”....................................................................................................................................... 43 4.1 INTRODUCTION................................................................................................................................ 43 4.2 SCOPE ........................................................................................................................................... 43 4.3 PLANNING....................................................................................................................................... 43 4.4 PLANNING OF INDIVIDUAL LIFTING OPERATIONS ................................................................................. 44 4.5 RISK ASSESSMENT .......................................................................................................................... 45 4.6 LIFT CATEGORIES ............................................................................................................................ 46 4.7 MINIMUM QUALIFICATIONS ............................................................................................................... 47 4.8 OPERATOR OR CONTROL REQUIREMENTS ......................................................................................... 48

4.8.1 Mobile Crane Operations....................................................................................................... 48 4.8.2 Forklift Truck Operations ....................................................................................................... 49 4.8.3 Rigging Loft Control............................................................................................................... 50 4.8.4 Webbing and Round slings.................................................................................................... 52 On BP operations sites clear guidance is given within the SSoW for control and planning requirements of webbing and round slings, on construction sites the use of this procedure is often not practical. However Contractor shall control the use of webbing and round slings via a written procedure approved by Company.......................................................................................................................................... 52 4.8.5 Man Riding Operations.......................................................................................................... 52

4.9 PRE MAN-RIDING CHECKLIST.................................................................................................... 55


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1 General

1.1 Introduction

This document has been produced by using the majority of existing Company’s safe operating procedures and other load lifting and movement related guidance supplied by various Company operations worldwide and the golden rules. The information received has been checked against the current information, the guidance of Company procedures and additional information and guidance based on “Industry Good Practice” has been added where relevant. The document is intended to be AzSPU construction site specific and has been made so by ensuring that as a minimum, the information and guidance contained herein complies with the requirements of international legislation and regulations in the main areas of oil and gas exploration. The document concentrates on the correct and safest way of carrying out lifting operations and caters for the fact that such operations will not always be performed by full-time riggers or lifting specialists. To manage this situation, a new set of competence standards have been created to accurately reflect the type and range of lifting activities performed by the various disciplines. These standards will also limit the type of operations personnel are authorised to carry out, unless they are to receive further training to the next level of competence and / or are to be working under the close supervision of more experienced personnel. Wherever possible, the lifting equipment and safe operating procedures also follow the guidance given in various national standards where the guidance is applicable and relevant. The document has been divided into 3 parts for easy reference as follows: • Section A – Management • Section B – Supervisors • Section C - Workforce Section A details Company policy with respect to lifting operations. This section specifies the minimum standards of lifting equipment acceptable to the Company and describes the various procedures that will ensure the safe use of the equipment and its ongoing integrity. This includes the routine maintenance and certification requirements to comply with international regulations. Finally, it sets minimum training levels and standards of competence for those people operating the lifting equipment or otherwise involved with lifting operations to increase safety and reduce the risk of incidents and accidents. Section B contains controlling / approved operating procedures. The operating procedures range from initial selection of the lifting equipment through procurement, required documentation and certification, correct storage, issue and control, quality of hired-in plant and equipment, quarantine of defective equipment, maintenance, repair and recertification and statutory inspection. This section “B” also contains “Company special instructions” and guidance on the required training and competence levels for personnel involved with lifting operations.


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Section C deals with the hands-on aspects of lifting operations. It starts with planning and risk assessment followed by pre-use inspection of the lifting equipment by the user. It contains various safe operating procedures for specific lifting operations such as crane operations, forklift truck operations, rigging loft control and man-riding with cranes and winches. It also refers to the various levels of competence required to perform the particular lifting operations

1.2 Purpose

The purpose of this document is to ensure that a uniform approach is adopted across the Major projects sites with regards to the supply and safe use of lifting equipment and accessories and specifically:

• To increase safety in lifting operations.

• To ensure compliance with relevant legislation / regulations.

• To ensure the supply of suitable equipment.

• To ensure all lifting equipment is fully certified, traceable and marked accordingly.

• To ensure that lifting equipment is held in a secure location and that its movements are controlled.

• To ensure continuing integrity of lifting equipment by appropriate maintenance and inspection programmes.

• To ensure that lifting equipment is examined prior to and after use.

• To inform personnel of their obligations to perform lifting operations safely.

• To ensure that all lifts are risk assessed and risks are reduced to acceptable levels.

• To ensure that all lifting operations are planned and implemented with the required levels of competence, organisation and supervision.

• To ensure that accurate and meaningful records are maintained.

It is accepted that a Contractor may have their own systems and procedures and may choose to use those rather than AzSPU procedures, However this document lays out a minimum standard or requirement that must be contained in a Contractor’s systems and procedures.

If the Contractor wishes to use their own system or procedures those systems and procedures must be approved by the Company Lifting Technical Authority

1.3 Scope

The scope of this document includes, but may not be limited to lifting equipment identified in the 'Written Scheme of Examination'. Contractor owned lifting equipment shall be maintained to comply with the Company’s policy but is the responsibility of the Contractor. The guidance is intended for all personnel involved with lifting operations. This includes Contractor personnel working on the Company worksites.


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1.4 References

Document Number Document Title ASI American Standards Institute AWS American Welding Society AS Australian Standards AZSPU-HSSE-DOC-00056-2 Safe System of Work for Lifting Operations AZSPU-HSSE-DOC-00059-2 Safe System of Work for Man Riding Operations BS British Standards EN European Standards ISO International Standards IMCA Guidelines for Lifting Operations NSL International Rigging and Lifting Handbook NSL Safe Cargo Handling – Good & Bad Practice Pocketbook OPSB-OPS-PRC-063 AzSPU Portable Lifting Equipment

1.5 Definitions

Written Scheme of Examination: Document which identifies the statutory inspections and periods between inspections required to comply with regulations internationally. Lifting Equipment: Equipment for lifting, lowering and suspending loads which includes lifting appliances and lifting accessories.

Lifting Appliances: Devices capable of lifting or lowering loads and includes its attachments used for anchoring, fixing or supporting it e.g., Cranes, forklift trucks, lifts, suspended cradles, powered hoists, manual hoists, lever hoists, rope hoists, winches, beam trolleys, beam clamps, sheave blocks, runway beams, padeyes, etc. Lifting Accessory (gear): Are those components for attaching load(s) to lifting machinery / equipment, such as slings, shackles, eyebolts, hooks, etc. Lifting Operation: An operation concerned with the lifting, lowering or suspension of a load. Lifting Equipment Register: A register which identifies the type, description and location of all the Company’s lifting equipment located at a specific location, e.g. platform’s fixed lifting equipment registers. Nominated Competent Person: Is a person who has been designated competent, by virtue of training and experience, for the control and where necessary the thorough examination of lifting equipment and accessories. The competent person is also responsible for the safe use of lifting equipment.


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Lifting Equipment Contractor: Contractor who has been appointed to provide lifting equipment to the Company’s Operations. In addition, the Contractor has the responsibility for carrying out the thorough examination of designated lifting equipment as directed.

1.6 Abbreviations

Abbreviation/ Acronym Description

ABL Actual Breaking Load ASME American Society of Mechanical Engineers BDJF Baku Deepwater Jacket Factory

BS British Standards COG Centre of Gravity EAL Engineering Standards Award Body

ECITB Engineering and Construction Industry Training Board. FC Fibre Core FLT Fork Lift Truck

IMDG Code International Maritime Dangerous Goods Code IWRC Independent Wire Rope Core

LOLER Lifting Operations and Lifting Equipment Regulations SI 1998 No 2307. MEWP Mobile Elevated Work Platform MBL Minimum Breaking Load. MPI Magnetic Particle Inspection. NDE Non-destructive Examination. NDT Non-destructive Test. PPE Personal protective equipment

PUWER The Provision and Use of Work Equipment Regulations 1998 RTC Risk it, Talk it , Check it

RTITB Road Transport Industry Training. SSoW Safe System of Work SWL Safe Working Load. UT Ultrasonic Examination

UKOOA UK Offshore Operator Association WLL Working Load Limit

2 Section “A”

2.1 Activities – Controlling procedures

The activities related to the certification, testing, control, examination and safe use of fixed lifting, and specialised portable lifting equipment, are controlled by the Support Procedures for Safe Operations as follows:

2.1.1 Equipment

This procedure is intended to guarantee the quality of lifting equipment arriving at Company worksites and the on-going integrity of the lifting equipment while in service.


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Correct selection of appropriate lifting equipment and accessories

Purchase of new lifting equipment and accessories

Quality of sub-Contractor’s lifting equipment

Statutory inspections on lifting equipment

2.1.2 People

This procedure is intended to make lifting operations safer for personnel involved with them

Planning lifting operations

Risk assessment

Training / Competence

Safe use of lifting equipment and accessories

General cranes operations

2.2 Roles and Responsibilities

2.2.1 Site Manager

Is responsible for ensuring that all personnel on the worksite, comply with the requirements of international regulations and all other appropriate procedures contained in this document as a minimum.

The Site Manager is also responsible for implementing the standard presented in this document during all operations associated with the facility. He is also committed to take a proactive role in seeking out and recommending improvements to this standard.

2.2.2 Maintenance Supervisor

The Maintenance Supervisor is responsible for ensuring that inspection and maintenance of all lifting devices complies with this document. The Maintenance Supervisor shall ensure that suitable work instructions and activities are prepared and approved for maintenance / inspection work on lifting devices on a continuing basis. The Maintenance Supervisor is the recipient of non-conformities notices for any lifting devices and is responsible for ensuring that non-conformances are correctly addressed.

2.2.3 Lifting Superintendent

The lifting Superintendent is the designated ‘responsible person’ in overall charge of lifting equipment and operations on the work site. The Lifting Superintendent must ensure that all personnel involved in lifting operations are fully conversant with the regulations and the guidance contained in this document.


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The Lifting Superintendent is responsible for:

Ensuring all planned lifting and routine lifting operations, by AzSPU and, or the Contractor, have been the subject of a risk assessment session and are part of a subsequent risk mitigation plan that forms the procedure to do the work.

Writing required lifting plans or assisting methods and engineering teams with the writing of plans

Liaising with the lifting service Contractor(s).

Co-ordinating statutory inspections.

Liaising with the Maintenance Superintendent on maintenance and tools associated with lifting operations.

Maintaining a Register of Lifting Equipment owned by Company / Contractor and that ensures all items have proper identification including Colour Coding and are correctly certified and controlled as required by this Standard.

Authorising the purchase of new lifting equipment.

Specifying the testing / proof load requirements included in this document.

Specifying the marking requirements.

2.2.4 Foreman / Supervisor

The Foreman / Supervisor is responsible for:

Responsible for ensuring that all lifting operations are assessed for intrinsic and contingent risk and hazard prior to being carried out and are carried out in accordance with the appropriate procedures as detailed in this document.

Responsible for ensuring that the daily maintenance checks have been carried out and that operating checks are carried out prior to the use of any crane.

Responsible for ensuring the appropriate level of authorisation for crane use and lifting activities has been obtained via the AzSPU or Contractor permit to work system.

Ensuring that lifting equipment use is documented in a ‘T’ Card or similar Logging System.

2.2.5 Crane Operators (Mobile, Crawler and overhead)

The crane operators are responsible for carrying out their duties safely, carrying out daily inspections on the type of equipment they use in accordance with the correct site and bp procedures under the supervision of the rigging supervisor or Foreman. Having a clear understanding of the work to be done and the risk assessment

for the proposed lift

Safely coordinating each job with operators and other crewmembers

Placing themselves where they can safely carryout the operation and can clearly see the Banksman or communicate via radio


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Use standard crane signals unless other methods of signalling, such as two way radios, flags, whistles or other means have been agreed upon

2.2.6 Banksman / Signal Person / Basic Slinger

The primary duty of a Banksman is as a signal person to assist the crane operator to perform safe and efficient lifts. Crane operators depend on signal persons designated to assist them in making movements without endangering people property or the environment. He will also have a basic understanding of slinging and required angles as well as attachments and end terminations such as plate clamps, shackles etc. Banksman is referred to as “Dogman” in Australian Standard nomenclature. Banksmen are responsible for:

Having a clear understanding of the work to be done and the risk assessment

for the proposed lift

Safely coordinating each job with operators and other crewmembers

Placing themselves where they can safely observe the entire operation and can be clearly seen by the crane operator

Use standard crane signals unless other methods of signalling, such as two way radios, flags, whistles or other means have been agreed upon

2.2.7 Riggers

The rigger shall be responsible for:

Familiarising themselves with the risk assessment and mitigation plan for each and every lifting and load movement activity they are to be involved in, and ensuring their work colleagues are also familiar with the job risk assessment.

The safe rigging of the load including set-up of portable lifting equipment and the correct selection of the rigging equipment.

Maintaining lifting gear stock levels in the rigging loft including inspection of the lifting equipment condition prior to its use and the safe return of used equipment to the rigging loft.

Returning any equipment deemed to be damaged or not fit for purpose due to certification or tagging issues to the lifting gear Contractor for recertification via the Quarantine Bin or container.

Placing defective lifting equipment in the Quarantine bin and arranging with the materials controller for their return to the lifting gear Contractor for inspection and testing or disposal.

Proper care and maintenance of lifting gear in the rigging loft, such as corrosion prevention.


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2.3 Third Party Responsibilities (Sub Contractors) The following method of controlling loose lifting equipment and specialised lifting operations has been established for all equipment brought onto the Company’s work sites by third parties. Third party is to inform the Lifting Supervisor of the intention to bring lifting equipment to the particular worksite.

Lifting Supervisor is responsible for verifying that the 3rd party lifting equipment satisfies regulatory requirements and the requirements in this document.

a) Condition / fitness for purpose.

b) SWL.

c) Serial Nos.

d) Valid certificate.

e) Colour code.

f) Current third party inspection report

The third party must ensure (and be able to demonstrate) that their personnel have received adequate training in the safe use of lifting equipment. Where applicable, their appointed personnel must also have experience in performing risk assessments for their particular lifting activities. Deliveries of any materials and / or equipment having lifting accessories attached must be accompanied by the relevant certification as per the requirements of this document

"Third” Party to provide: a) A register containing certificates for all their items of lifting equipment.

b) Equipment with Safe Working Load (SWL) clearly stamped on each item.

c) Equipment with current certification.

d) Individually identified equipment e.g. a serial number / ID number.

e) Adequately secure storage and protection from weather.

f) Controlling system to account for issue / use of the lifting equipment.

g) Risk assessments and operational planning for tasks using their specific lifting equipment.

h) Adequately trained personnel to operate their lifting equipment. By compliance with the above, “Third” parties will comply with the requirements of this document for lifting equipment rules. This will also form part of the contractual requirements.

Examples of third parties who are likely to send their own lifting equipment to the Company’s work sites are:


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• Construction / maintenance Contractors

• Specialist equipment Contractors (e.g. Turbine maintenance engineers)

• Equipment vendors that supply slings, shackles, spreader bars etc

2.4 Training and Competence

It is a requirement that all personnel operating cranes, forklift trucks and other lifting equipment shall have the necessary training to enable them to carry out the work safely. Thereafter, once adequate experience has been gained, they must be able to formally demonstrate their competence in their specific area of operations. Until recently it was difficult if not impossible to assess individuals competence as the criteria against which they were to be measured was either vague or indeed did not exist. The main disciplines such as crane and forklift truck operation were adequately covered but the subject of rigging and lifting operations were vague to say the least. There were standards of competence for the top end, e.g. for full-time riggers but the majority of personnel involved with rigging and lifting are not full time riggers. This gap was identified and a new set of competence standards were developed to accurately reflect the type of lifting operations undertaken by these personnel. These were created as “internal competence standards” which allows individual companies to modify and adapt them to find the best fit with the Contractor’s specific lifting operations and have been approved by the UK Oil and Gas Industry advisory body (“Stepchange”) This section is listed as guidance and any competency based program should be developed using a similar format. This format must be approved by the Lifting Technical Authority. The competence standards are as follows:

2.4.1 Crane Operators Crane Operators should be trained and assessed in accordance with the industry

accepted standard of competence. The training is to be in line with official guidance which dictates the level of achievement expected.

Crane operators should hold a local licence for the category of crane they will be operating and should be assessed by a third party to the requirements of ISO 15513-2000 or similar auditable standard to ensure they have an understanding of the requirements and are familiar with the functions, load indicator system, pre use inspections etc., and are suitably competent to operate the appropriate cranes on major projects sites. In the absence of specific operator competence criteria for lifting personnel baskets etc with the crane, it is a requirement for operators to receive training in the safe use of Work & Personnel Baskets and those operators must be deemed competent by a third party skills assessor. Clear guidelines for man riding operations are given in the AZSPU-HSSE-DOC-00059-2 - Safe System of Work for Man Riding Operations and this document. All crane operators (including fully qualified) should be re-assessed every two years by qualified skills assessors.


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2.4.2 Forklift Truck Operators Forklift Truck Operators should be trained and assessed in accordance with the RTITB standard of competence or auditable similar standard, which addresses:

1 Indentifying the correct forklift for the task

2 Pre-start up checks and inspection.

3 Driving skills.

4 Manoeuvring in confined spaces.

5 Travelling up / down / across inclines with a load.

6 Reversing with a load.

7 Stacking loads.

8 Removing loads from a stack.

9 Correct positioning of loads on vehicles.

10 Safe parking etc.

2.4.3 Banksman / Signal Person / Basic Slinger Banksman should be trained to the guidance within ISO 15513-2000 / EAL, ECITB or similar

auditable standard to ensure they have an understanding of the requirements and are familiar with crane functions, slinging and angles, pre use inspections, line of fire etc.

2.4.4 Riggers

Riggers should be trained and assessed in accordance with recognised industry standards such as EAL, or ECITB. There are two main levels of competence, level 1 and level 2. The level 1 competence is for personnel who are involved in lifting operations as part of a team, working under supervision to a lifting plan created by others. The level 2 competence is for personnel who create the lifting plan and supervise lifting operations. The basic competencies covered are:

1 Planning lifting and positioning operations, including definition of work

instructions and inspection of load.

2 Preparing resources including selection, pre inspection and preparation of slings and lifting gear.

3 Rigging lifting gear and lifting points and attaching slings.

4 Working with cranes and lifting appliances to undertake and control lifting operations.

5 Dismantling and storing rigging and slinging equipment.


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Competence assessments should be carried out on an individual basis and would normally be conducted by skills assessors trained to national standards.

Major projects construction sites must have Level 2 riggers or equivalents as supervisors or foreman. Note: There is a relatively new level 3 competence and this is designed so that the level 2 Rigger can take a job further before requesting engineering support. This level of competence is not covered in this document.

2.4.5 Lifting Operations – Internal Competence Standard

The Contractor’s staff and dedicated core contract staff who are NOT riggers but are engaged in lifting operations must have received training to a level which allows them to complete the lifting operation safely. Contractors and suppliers of personnel are responsible for the training of their own staff / workforce and must be able to demonstrate their competence as and when required by Company on its work sites. Training to the required competence standards is available in Azerbaijan and has been produced in line with BP / AIOC requirements for these personnel engaged in rigging, lifting, deck operations, general cargo handling activities and maintenance tasks, which involve lifting. The purpose of these programmes is to raise the competence levels of those personnel, improve safety in lifting operations and thereby reduce accidents. These programmes conform with the guidance given by the UK Oil and Gas Industry and relevant award bodies such as EAL and CITB. Its should also be noted that training must be provided by BP / AIOC approved specialist training companies and course content and curriculum must be approved by the Company Technical Lifting Authority The contractor may and is encouraged to carryout assessments. Contractors are reminded that training and assessments are different. In-house assessments may assist with appraisals or identify gaps or additional training requirements but formal training must always be provided by an approved training company. The key steps that personnel have to pass through to be deemed competent:

1 Step 1 comprises initial training and assessment. Personnel can achieve this

by attending and completing the following courses:

o EAL Banksman / Slinger course

o Basic communication course for hand-held radios

At the completion of Step 1, the level of competency is deemed sufficient for that person to conduct basic lifting operations such as banking a crane and general slinging. Any other lifting tasks should be under the direct supervision of a competent person (Level 2).


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2 Step 2 comprises initial training and assessment. Personnel can achieve this by attending and completing the following courses:

o EAL Basic Rigging course

At the completion of Step 2, the level of competency is deemed sufficient for that person to conduct basic lifting operations such as banking a crane, slinging, general chain block, pull lift and similar equipment. Other lifting tasks should be under the direct supervision of a competent person (Level 2).

3 Step 3 is the step into the level “1” Rigger training and assessments, the candidates must firstly complete stage one and two then undertake specific training on “key elements” that will give the level 1 rigger the competency building blocks. Personnel can achieve this by attending and completing the following courses:

o Intermediate rigging and lifting course ( specialised techniques )

o Planning a lifting operation and working to and understanding the plan

o Advanced equipment inspection

o Safe use and inspection of webbing and round slings

o Use of lifting clamps and handling plate, rolled steel

o Appreciation course for the safe use and selection of Cranes, Forklifts, MEWP’s and specialised equipment

After these training sessions the candidates for level 2 will have been identified. On completion of level 1 the successful candidates will be deemed competent to carryout all lifting operations that fall into the simple and routine categories but will still require an element of supervision from the level 2’s. They will work supervised on complicated / complex tasks

4 Step 4 is the required training for level 2 rigger “Supervisor”. On training completion

he will affectively meet the requirements / qualification for sitting his EAL or ECITB award

o Advanced rigging and lifting course ( specialised equipment )

o Advanced planning of lifting operations

o Control and inspection of Equipment ( Rigging Loft Keeper )

o Safe use, technical requirements and inspection of wire ropes

o Grommets and cable laid slings

o Container movements and certification requirements for all types

o Selection of Cranes, Forklifts, MEWP’s and specialised equipment

o Appointed Persons

There will also be ongoing performance development and additional training maybe required for specialised tasks.


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Every 2 years, personnel will sit a one-day reassessment “by training company” consisting of a test of practical skills and a test of knowledge to ensure competence is being maintained / improved or to determine if refresher training is required. Supervision will be carried out by the Lifting Supervisor who also acts as the witness and assessor.

2.4.6 Overhead crane operators

Overhead crane operators “seat or pendent operators” shall be trained and assessed to ensure competency, part of this training shall also include Banksman slinging to give a better understanding of what’s required at ground level to assist with lifting operations. All crane operators (including fully qualified) should be re-assessed every two years by qualified skills assessors.

2.4.7 Rigging Loft Keepers

Appropriate training is required for anyone signing out lifting equipment from the rigging loft, the control element is just as important as the inspection and the rigging loft keeper should know and understand how to implement a workable practical system. Specialised training is required for this position

2.4.8 MEWP’s (Mobile Elevated Work Platform)

All operators shall be appropriately trained and deemed competent by a specialised BP / AIOC approved training company

2.4.9 HIAB’s

All operators of HIAB’s or knuckle boom cranes shall be appropriately trained and deemed competent by a specialised BP / AIOC approved training company

2.5 Completing the Standards

Prior to embarking on any of the competence programmes, it is essential that personnel have successfully completed the relevant training course(s) as specified in the “Experience / Qualifications” section of the individual competence standard. Thereafter, training and assessment begins the day the person arrives on the worksite. The competence standard personnel will be working towards is specific to what they will be expected to know and the task they will be required to carry out. This is indicated through the performance and knowledge criteria. The most important aspect to realise during the training and assessment of personnel, and indeed once they have attained the specific standard of competence, is that they understand their own personal limitations. Personnel must work within their limitations to be sure and safe. The complete standards are divided into sections comprising:

1. Roles and responsibilities.


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2. Prior Qualifications. 3. Performance Criteria. 4. Knowledge Criteria. 5. Performance Activities.

If used the delegate’s logbook comprises performance activities and safety information. The Assessor’s logbook / computer system contains the performance activities and related activity questions.

For every new task or activity personnel are assigned, the procedure shall be for a more experienced / competent crew member to:

1 Fully explain the lifting operation, usually via a toolbox talk. 2 Demonstrate how it must be done properly, including all the safety precautions. 3 Allow personnel to assist / participate in the lifting operation. 4 Allow personnel to complete the lifting operation under supervision*.

* At this stage (3 or 4), personnel can have the task / activity recorded and ticked-off by the Assessor / Supervisor in their logbook as part of their evidence of competence.

Personnel must never attempt a new task / activity on their own.

Each activity listed in the competence logbook must be, where applicable, completed correctly and safely on three separate occasions. At the end of each shift personnel are required to contact the appointed assessor, who will record the completed performance activities. This is to ensure against the accidental loss of the logbook and previously completed activities.

Once the logbook is complete, personnel will be required to sit a theoretical multi-choice test to establish that they have an acceptable level of knowledge on the subject. Thereafter, personnel will be reassessed every two years to ensure that they are maintaining a satisfactory level of competence, if not increasing it. All appeals regarding assessment decisions shall be recorded by the assessor and lodged, by the delegate, with the line manager. The appeal must be in writing and lodged within 2-3 days of the decision. The Lifting Technical Authority will examine assessment evidence and make a final decision. This will be relayed to the delegate in writing and accurate, comprehensive record will be kept.

Standard Levels

Although the steps to obtain competence are listed as 1 – 4 the grade of personnel are recorded differently. Personnel can be identified by level or grade

Basic Level – Banksman Slinger / Basic Rigger • Load handlers, General Crew, “Anyone handling cargo with cranes”

Performing Deck Operations | Banksman Slinger


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• Maintenance Technicians, Pipe Fitters, Platers, Welders, etc Performing Maintenance Operations | Slinging & Lifting

Anyone working at this level must be supervised and appropriately trained as per the competency listed above ( steps 1 & 2 ) Level 1 • Level 1 Riggers

Performing Supervised Lifting Operations

Anyone working at this level must be supervised when required and appropriately trained as per the competency listed above ( steps 1, 2 & 3 )

Level 2 • Level 2 Riggers ( Supervisors )

Performing Lifting Operations | Specialised Lifting | Planning | Risk Assessments | Mentoring and Supervision | Control of operation | Control of equipment

Steps 1 – 4 must have been completed. After obtaining this level work on all categories maybe be carried out (simple – complex)

The site rigging superintendent who sits above the Level 2 riggers will control the teams and assist when required to ensure work is carried safely. The rigging superintendent will be qualified to not less than the EAL level 2 standard

2.6 Assessment Standards

Copies of the actual standards, log books, assessor’s documentation are available on request by contacting the BP Technical Lifting Authority

2.7 Hands Free Lifting

Contactor shall were possible shall plan for hands free lifting, if contact must be made with the load it shall only be between waist and shoulder level and be appropriately assessed via risk assessment.

2.8 Planning of Lifting operations

It is a requirement of international regulations that every lifting operation is competently planned. The lifting operation must also be appropriately supervised and carried out in a safe manner. Detailed guidance on the planning of Routine, Simple, Complicated and


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Complex lifting operations is given in Section “C” of this document and the AZSPU-HSSE-DOC-00056-2 – Safe System of Work for Lifting Operations Two areas are highlighted in this section are:

2.8.1 General Planning

It is understood that with the nature of an oil / gas facility construction, that literally hundreds of lifts are carried out daily and to forward a written plan for each lift is not easy to organise, however some form of planning and risk assessment must be carried out before each lift can be carried out. This can be in the form of a developed carbon copy pocket book, An RTC type pre task check sheet or any other method but must be approved by the Company Lifting Technical Authority. The assessment should be carried out on site, but must be in an auditable format and performed by a rigging Foreman, or a competent person for the level of lift or operation that is to be carried out and involving the team who are to be engaged in the task. During the on site planning assessment, if the task is out with the criteria on the pocket card or similar, or above the competency level of the rigger or lifting team carrying out the task, the rigging superintendent or his delegate should plan, convene a full risk assessment, produce a mitigation statement, record and supervise the operation.

2.8.2 Heavy Lifts

All heavy lifts require detailed planning and risk assessments. This detailed planning should be carried out by the methods set down in the risk assessment procedures associated with this document or is performed by the relevant engineering team that has the requisite practical and theoretical knowledge and experience of planning lifting operations. If the Contractor wishes to use his own system or format they must as a minimum include the following criteria. The planning must include but is not limited to:

Detailed step by step of lift sequence Detail the risks and hazards associated with the intended lifting operation including:

• Details of COG and rigging mitigations to ensure an even lift • Additional cranes, forklifts, MEWP’s to be used • Attachment of rigging to equipment to be lifted • Ground preparation route and marking • Barrier areas – 110% of boom length • Personnel control • Load pickup point • Movements • Direction changes • Load transfers


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• Lifting over equipment or process • Landing location preparation dimensional control

Detailed drawings

• Illustrations of lift journey and at the least the start and finish points in

sufficient detail to illustrate lift • Details of COG rigging mitigations / adjustments to ensure even lift • Ground details of route to be travelled • Rigging detail i.e. SWL’s, angles, lifting points, spreader / lifting beams • Potential clashes • Ground bearing pressures at critical radius, load and position.

Weight

• Accurate weight verification or detailed weight study / report • Pre weigh-in results • Contingency weight percentage • Weight of rigging

Crane or Cranes to be used

• Boom lengths • Counterweight configuration • Superlift configuration • Actual hook load • Capacity at radius • Percentage of load chart capacity

Rigging and lifting points

• Sling type, SWL, Angle to be used, bend radius and calculation /

verification of suitability • Lifting beam detail, SWL at load centres and tare weight • Padeye detail, SWL or WLL, NDT status, shackle suitability and potential

clashes • Shackle types, SWL’s • Link plate’s or additional equipment for altering length or adjustments • Full certification and NDT reports are to be made available for rigging and

cranes to Company if required.

Risk assessments

• The weight of the load. • Position / height of the centre of gravity. • Stability of the load. • Size and shape of the load. • Protection of load during lift. • Availability of dedicated lifting points on the load. • Availability of suitable rigging. • Protection of rigging against sharp edges.


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• Capacity of the crane / hoisting equipment. • Availability of certified anchor points / support steelwork. • Maximum height the load has to be lifted. • Any dynamic factors (including sudden movement of equipment etc). • Route to be travelled. • Marked cleared route. • Barrierd areas – 110% of boom length. • Evacuation of portacabins or offices within the 110% of crane boom

working area. • Evacuation plan. • Obstructions. • Control of the lift. • Hazards to other personnel. • Number of Banksmen and watchers required. • Communications. • Deck / floor / ground capacity for lifting and landing the load. • The need for tag lines. • Available light. • Experience / competence of personnel. • Weather conditions and acceptance criteria.

All above items maybe collated in to any format the Contractor see’s fit. Lifting plans for single crane lifts must be available for review a minimum of 7 days before lift is to commence. And for tandem or multi crane lifts the plans should be made available not less than 14 days before planed lift On major or complicated lifts a pre lift risk assessment meeting or further mitigation plan meetings will be held prior to the task commencing. The complexity of the lift will determine the meeting frequency and preparation required. Contractor developed pre task check sheets will be used to ensure highlighted points are addressed and mitigated prior to job start. This document will also act as BP “Company” approval.

2.9 Lifting Over Live Plant

If contractor is lifting over plant, pipes or stored energy it is responsible for developing a lifting over live plant procedure, this procedure should give sufficient detail to address all risks and give adequate mitigation plans. This procedure shall also sufficient detail on justification for carrying out the task and limiting factors. Procedure shall be approved by the Company Lifting Technical Authority and HSE site manager.

Lifting plans must be available for review a minimum of 7 days before lift is to commence. And for tandem or multi crane lifts the plans should be made available not less than 14 days before planed lift


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2.10 Ground Condition and Loadings If contractor is lifting on un-known or un-tested ground a procedure shall be required, this procedure should give sufficient detail to address all risks and give adequate mitigation plans Procedure shall be approved by the Company Lifting Technical Authority and HSE site manager.

As part of any lifting plan the loads shall be calculated and clearly visible, the category of lift will also be determined as not less than complicated and require signoff by the Lifting Technical Authority or his delegate

2.11 Provision of SOCAR HC Crawler Cranes

The crawler cranes at the Baku Deep Water Jacket Facility ( BDWJF ) are currently 26 years old and on job completion of the next phase of work will be over 30 years old, they have had little maintenance over the years and have minimal assurance that they are suitable to carry out work for the next 3 or 4 years. Before they can be used on the project they will require an overhaul. A general minimum work scope is listed in section 2.14. The Lifting Technical Authority or his delegate should be consulted on the status of the overhauls and he shall authorise repairs as required. Cranes used for man riding require an upgrade or modification to the brake system to ensure they meet the requirements of current legislation and the guidelines within the SSoW for man riding operations. More detail is available in section C It should also be noted that when the BDWJF cranes are used for tandem lifts involving slewing and direction changes. It should not be an assumption that the cranes can be used at 100% of capacity, detailed engineering will be required when using cranes in tandem over 80% of capacity and approval must be given by the Lifting Technical Authority If used the overhead cranes at BDWJF will also require re-certification and possible overhaul work, the scope and condition of these cranes and support structures is yet to be determined. An in-depth inspection will highlight the areas that require attention but the cranes must meet the certification requirements of section 3.4. The Lifting Technical Authority or his delegate should be consulted on the status of the overhauls or repair work and he shall authorise repairs as required.

Should larger cranes be required, they should meet as a minimum the certification requirements of section 3.5

2.12 Crane Certification A full documentation package shall be presented on overhaul completion with supporting test certificates. This package should include as a minimum:


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• NDT reports to specified acceptance criteria • Weld repairs and procedures and materials used • Photographs and illustrations • Datum points or reference to manufactures original data. • Destruction samples for wire ropes • List of replaced components • Test Certification

2.13 Maintenance and Certification

The Contractor is responsible for the maintenance and certification requirements of refurbished cranes. He shall design a maintenance and inspection programme and submit to Company for approval. It should also be noted that it cannot automatically be assumed that these cranes will be capable of lifting the heavy loads they were designed for. Some cranes my need to be down rated based on the results of overhauls. Full certification requirements are listed in section 3.5

NDT shall be carried out to the requirements and acceptance criteria of AWS D1.1, fillet welds and cast material such as hook blocks may be inspected using Magnetic Particle Inspection with a “Y6” YOKE magnet and full penetration welds shall be inspected using the Ultrasonic technique. The noted methods above may not always be practical or sufficient for the components that are being examined, when required NDT my be carried out by an alternative or more appropriate methods.

2.14 Overhaul and Inspection

As a minimum the following items should be examined:

Boom Sections

• Lightly blast just to remove paint then NDT inspection ( Foot & Head sections ) • Re-Paint Foot & Head sections after NDT ( Colour to be identified by Company ) • Inspection of boom mid section ( + NDT ) • Inspect boom joining pins ( Dimensional and NDT ) • Replace / Inspect connection bolts as required with appropriate grade • Boom pennant line inspection as required

NDT • Boom - 100% Foot and Tip sections & 10% other • Boom foot pins • Sheaves – 100% ( Hoist & Luff ) • Sheave pins • Back mast top and bottom mountings • Back mast sheave pins • Back mast foot pins • Car Cab – Load Path • Tracks – hard faced areas.


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Hook Blocks

• Strip down • NDT Side plates, Sheaves, load pins ( 100 % ) • Re-assemble • Load Test

Ropes & Pennant lines

• Destruction test on hoist and boom ropes • Full line inspection as required. • Load test of boom pennant lines

Crane Cab

• Load indicator – verification / calibration • Controls – leavers, linkages, markings inspection to PUWER requirements

Slew ring

• Rocking Motions • Slew ring motor inspections • Slewing motor drive face inspection • Oil and grease samples – independently analysed • Whip / lash checks • Bolt torque checks ( have required equipment )

Counterweights • Verification of weight • NDT of support / hanging mountings

Winches • Inspect / Replace mounting bolts • Main drum, drum bearings and load shaft • Hydraulic hose inspection • Control valves • Brake linings and surfaces • Oil leaks to be repaired

Hydraulics • Pumps • Hoses • Valves • Filters • Oil Samples – independently analysed • Oil flush required


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Engines • Compression Tests • Oil Samples – independently analysed • Service • Oil Leak repairs as required • Other work as required

Drive train • Service • Coupling inspection • Track inspection • Oil Leak repairs as required • Other work as required

Crane re-assembly

• All inspected parts to be fitted • Boom alignment checks • Crane alignment / levelling checks • Full function pre use test • Full pre use inspection

Re – certification of cranes

• Cranes should be tested to requirements of BS EN 7121 or ASME 30.5 as per

SSoW 56-2 requirements and the requirements of this document. • Full certification and refurbish dossier shall be included as part of the scope. This is

to include NDT reports, pictures, datum points, certification

2.15 Control of Rigging Equipment

Guidance on rigging loft control is covered in section C and shows that the rigging loft keeper is responsible for the condition and control of the equipment. Contactor may use an approved system if required, however the rigging loft will be regularly audited to ensure that it is appropriately controlled on all shifts and areas of the worksite. A system of inspection for equipment not regularly returned to the rigging loft should be developed to ensure equipment is always in a serviceable condition. When developed must be approved by the Lifting Technical Authority

2.16 Third Party Inspection

In general, references to manufacturing codes and standards have been purposely avoided in this document. The western affiliated Inspection companies in Azerbaijan are currently working to the


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required American, British, European standards and can offer help and guidance on certification requirements. The third party inspection companies are constantly audited and guided to work within international standards. If the equipment will be used on a site it shall be load tested or visually examined to the appropriate American, British, European standard. All lifting equipment must be tested and certified to international standards. All lifting equipment must be visually examined and certified by a third party company at a minimum of six monthly intervals, no self certification will be carried out on controlled or Major Projects sites.

2.17 Lifting Operations Audits

The Company are committed to achieving the highest health, safety and environmental performance with the aim of creating and maintaining a safe and healthy workforce. To this end the Company will be responsible for ensuring that all lifting operations are carried out in a safe and effective manner and all lifting equipment is safe for use and correctly maintained. Protection of persons and the realisation of safe lifting operations will be achieved by adhering to the guidance given in the Company document with compliance monitored through regular audits to ensure that:

• All lifting operations will fully comply with all relevant legislation and guidance. • Personnel involved in lifting operations and the maintenance of equipment will be fully

competent and appropriately trained for any task they may have to undertake. • The use and implementation of strict audit, monitoring and inspection / testing regimes.

Where Contractors and their sub-Contractors bring their lifting equipment or personnel on board any Company installation or worksite, they will be required to demonstrate standards and practices which are compatible with the Company requirements and which satisfy current legislation. This procedure applies to all personnel and activities on the Company installations and worksites where the Company’s document applies and to all lifting operations and lifting equipment.


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2.17.1 Audits

All audits will be documented and provide actions and recommendations for improvement. All reports will be forwarded direct to the installation or worksite manager as appropriate who will assign actions to rectify any hazardous situations, non-conformances and measures to prevent recurrence. The audits (or technical surveys) will be carried out by the Lifting Technical Authority with assistance from the safety and quality teams. They will be carried out whenever there is “cause” such as an incident or at the discretion of the installation or worksite manager or appointed responsible person. Audits / technical surveys will be completed by means of a date recorded, formal report – Technical Survey which will be copied to the worksite manager. The manager will in turn copy the report to safety representatives as appropriate.

2.17.2 Monitoring

Effective monitoring of the Company’s lifting operations will be achieved by named personnel carrying out specific monitoring activities at defined intervals.

2.17.3 Audit Findings

All findings and non-conformances identified during audit and monitoring activities will be formally reported and recorded. Any non conformances found shall be highlighted in the audit report and an agreed timescale for rectification shall be noted for closeout purposes Reports will be kept active within Company electronic recording system to provide an audit trail and to demonstrate to regulators and external auditors that the system is robust and effective.

2.17.4 Follow up Audits

If required, follow up audits will be organized to ensure that all identified non conformances have been rectified / closed out

3 Section “B”

3.1 Introduction

The main purpose of this section of the document is to provide guidance and information to supervisory personnel responsible for or involved with lifting operations and equipment. The document is intended to be useful for the selection, certification requirements, purchasing, repair and ongoing maintenance. Having identified various areas and practices which have proved problematic in the past, a number of procedures are incorporated in the document to eliminate these problems and give clarity across major projects sites on future requirements.


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Note: For management policy governing lifting operations and lifting equipment, reference must be made to the Company document; Lifting Equipment Control and Operation Procedures -CDZZZZ-CM-PRO-5001, the policy document - section A.

The procedures and guidance contained within this document have been compiled with the following objectives in mind: 1. The prevention of equipment and accessory failure due to poor quality arising from

systems of approval at manufacturers and vendors, poor build quality in products.

2. The prevention of equipment and accessory failure due to inadequate / poor maintenance.

3. The prevention of equipment and accessory failure due to improved Inspection techniques (standardisation of inspection procedures).

The document also emphasises the pre-use examination of equipment and accessories as a number of incidents / accidents if not caused by misuse, are caused by using equipment and accessories which are faulty or have been previously damaged e.g: 1. Equipment and accessories can be damaged in transit.

2. Equipment and accessories can be misused and returned, damaged but not logged as in need of repair, to the rigging loft.

3. Repairs can sometimes be of poor quality.

4. Equipment and accessories in use can suffer damage from outside sources.

Note: It has also been known for new equipment to contain faults.

3.2 Scope

This section of procedure is intended to impart to the engineer the relevant information about the various standard types of lifting equipment available in the market place. In the interest of safety, any restrictions in the use of the equipment have also been highlighted. Where possible, for economic reasons, standard equipment should be used but for special cases it is possible to obtain customised gear to allow an awkward job to be carried out. Manufacturers should always be consulted regarding any customising of a product and under no circumstances should customising be carried out without the manufacturer’s written consent.

3.3 Design Notes

Generally, items of lifting equipment are manufactured to a standard or code but where neither British nor International standards exist to cover the design and / or manufacture the following criteria shall be met:

1. The equipment shall have a factor of safety commensurate with the type of usage it

is liable to be subjected to. This factor of safety will be 5:1 for normal lifting purposes and 10:1 for man-riding purposes.


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2. All materials used in the manufacture shall conform to a recognised national / international standard.

3. All welding shall conform to either recognised national / international standards or welding procedures approved by the Company.

4. All welds shall be of adequate strength suitable for the designed rated capacity of the equipment.

5. Each item shall be manufactured to the highest specified quality and standards of workmanship.

6. The surface of each item shall be prepared correctly prior to the application of a protective coating and if specified, this coating shall be suitable for use in a marine environment.

Reference to manufacturing codes and standards have been purposely avoided in this section. Should further information be required on any item or equipment type, reference should be made to the third party inspection provider or the Lifting Technical Authority.

3.4 Glossary of Terms

Alpha / numeric A combination of letters and / or numbers used for identification.

Calculated Deflections The deflections due to the safe load and proof loads,

computed by using the formula applicable to the particular circumstances.

Cantilever Beam Section of beam supported at one end only. Cargo Any liquid, solid or gaseous matter transported in a

container. Certificate of Examination A written declaration that an examination has been carried

out to the satisfaction of the independent competent person. Colour Code A method of marking equipment (normally with plastic tie-

wraps or paint) to give a visual indication of its certification status. This colour is changed every six months.

Competent Person Someone who is considered, by either the Lifting

Superintendent, the site Manager or the lifting equipment provider/manufacturer, to be experienced in the use of lifting equipment and who is familiar with, and has experience in, its operation. This person must also have the requisite knowledge and experience, both theoretical and practical, of the type of material under examination to certify with confidence whether it is free from patent defect and suitable in every way for the duty for which the material is required.

Container Any form of unit or device used for the transportation of

cargo as defined in BS EN 12079 (previous standard BS 7072). Also known as a cargo carrying unit (CCU).


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Dangerous Goods Substances defined as such but not limited to those in the CSG Code (e.g. CAA, COSHH, IMDG etc).

Drawn-up Dimension The minimum distance between the suspension level and

the bottom hook saddle. (Also known as closed-height). Effective Span The distance between the centres of the adjacent supports,

due to allowance being made for the end fixing, continuous beams and cantilevers.

Effort The pull on the hand chain or lever required to lift a specific

load (chain blocks and pullifts). The maximum effort allowable is relative to the maximum working load limit of the block.

Examination A visual examination by a competent person, carried out

carefully and critically, and supplemented by other means, such as measurement and where necessary non-destructive testing, in order to arrive at a reliable conclusion as to the condition and safety of the appliance. If necessary for the examination, part of the appliance shall be dismantled.

Extended Dimension This is the distance between the suspension level and the

bottom hook saddle of a chain block, when the bottom hook is in the extended position. It equals the sum of the drawn up dimension and the range of lift (or height of lift).

Factor of Safety The ratio of the load that would cause failure of an item of

lifting equipment to the load that is imposed upon it in service i.e. SWL (This is to allow for detrimental criteria such as wear and tear, dynamic loadings etc.).

Ferrule A compression fitting used to secure the eye of a wire rope. Frame The primary load bearing elements of the container. Gross Weight The maximum allowable weight of a loaded appliance which

is equal to the Tare weight (weight of empty appliance) plus the Safe Working Load (weight of cargo which may be carried by the appliance).

Hand Operated A block reeved with a load chain and operated by a hand Chain Hoist chain so as to give a mechanical advantage (also known as

a chain block). Headroom The maximum vertical distance between the item to be lifted

and the point of suspension of the hoisting machine. e.g. between the lifting padeyes and the underside of runway beam.

Height of Lift The amount of possible travel between the top and bottom

connection points (e.g. hooks) of a hoisting machine.


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Hook Load The total weight suspended from the hook. Inertia Forces The forces produced by a change of velocity. Inspection Is a visual inspection by a competent person, looking

carefully and critically for anything which may impair the safe and efficient working of the lifting equipment.

Lifting Appliance Any lifting machine or appliance used for the purpose of

raising, lowering or suspending persons or materials. Lifting Accessory A device, such as a sling, hook, shackle or eyebolt, used to

connect a load to a lifting appliance. Lifting Set Loose equipment and accessories used to connect the

container to the lifting appliance. Live Loads Any load except wind load that gives rise to a variation of

stress in a member. Such variation may be due to any change of position or magnitude of an externally applied load, or to the movement of the crane structure itself.

Load Encompasses the concept of either mass or force, and is

expressed in the appropriate units. Load Sensor A piece of equipment used for detecting the actual loadings

at a rigging point e.g. load cell shackle, test clock or compression load cell etc.

Measured Deflections The deflections measured in such a manner that they relate

to precisely the same conditions as those covering the calculated deflection.

Mode Factor A factor which takes into account the geometry of the sling

assembly, the number of parts and other constants as specified in the appropriate standard.

Operating Level The level on which the operator stands. Permissible Working The stress numerically equal to the basic stress, multiplied Stress by the relevant duty factor corresponding to the load. Plant / Identification A unique number given to an item of lifting equipment for Number registration purposes and to facilitate traceability. Proof Load Test The deliberate application of a predetermined overload to a

piece of lifting equipment. Range of Lift Is the vertical distance which the bottom hook travels

between the lowest (extended) and highest positions. Rigging Loft A container modified specifically to suit the storage of lifting

equipment (quite often fitted with lighting and heating).


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Runway Beam An overhead track for carrying loads which are moved along

it. Safe Working Is the maximum load (as certified by an independent Load (SWL) competent person) that an item of lifting equipment may

raise, lower or suspend under particular service conditions. This can be lower than the working load limit (WLL).

Sling Assembly A sling comprising various components eg. sling legs,

master links, etc. Structural Integrity Is provided by the strength of materials and their

arrangement to provide reliability of the load bearing structure.

Tank Container A container which consists of the tank or tanks, and the load

bearing structure. Thorough Examination Is very detailed examination by a competent person, looking

carefully and critically for anything which may impair the safe and efficient working of the lifting equipment. This examination shall include testing by the competent person where appropriate and may also include disassembly.

Tare The weight of the container without cargo. Tare weight shall

include all fixtures normally fixed to the container in service. Thimble A fitting used to protect the eye of the wire rope termination. Trigonometrical A method traditionally used to calculate the Working Load Method Limit (WLL) of slings at various angles of the legs. Uniform Load A method of rating multi-legged slings for use at any Method included angle between the sling legs of up to 90°, and in

special cases for two-legged and four-legged slings at any included angle between 90° and 120°.

This is the preferred method for rating general purpose

slings. Webbing A part of a flat lifting sling, comprising a woven narrow fabric,

generally of a coarse weave and multiple plies, the prime function of which is load bearing.

Wind Load The forces produced by the velocity of the wind, which is

assumed to act horizontally. Working Load The maximum load which an item of lifting equipment is Limit (WLL) designed to raise, lower or suspend.

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3.5 Crawler and Mobile Cranes

All mobile and crawler used on COP, SH2, STEP or Major Project sites must meet the requirements of the current AZSPU-HSSE-DOC-00056-2 and this document for lifting operations. Cranes shall be no older than 8 years old and preferably of modern design, cranes older than 8 years of age will be removed from site. Dispensations may be granted under certain circumstances. Further guidance is available from the “Company” Lifting Technical Authority

Particular attention must be paid to the certification requirements, ensuring that certification can be located for all ropes, hook blocks, wedge sockets, crane accessories and calibration or verification certificates for the Rated Capacity Indicator. (RCI)

Cranes maybe load tested to BS 7121 or ASME B30.5 but in either case the following certification must be supplied. All cranes must have a current service history and be serviced or maintained to a fixed regime, all records must be available to Company for review if required. Pre use Site inspections All mobile cranes that arrive on sites must undergo a pre-use inspection by an approved person as per the AZSPU-HSSE-DOC-00056-2 document for lifting operations. This pre-use inspection must be carried out before the crane starts any lifts or tasks on site, a copy of this report must be kept with the crane and on file at the site. Additional Crane certification, operators should also keep records in the cab of the crane, this package should include test certificates for all equipment and general rigging provided on the crane and where known dates of rope changes. The Crane Operator should also have available a copy of their operator’s certificate and assessment approval form. The operator should also provide his UKOOA medical or equivalent that meets the requirements of AZSPU-HSSE-DOC-00007-2 and section 4 of the SCOPE AND FREQUENCY OF ASSESSMENT document. Rope Certification, All plain ended ropes must be accompanied with a ABL / MBL certificate (F87 or equivalent), this certificate must display as a minimum the construction / configuration of the rope, grade of rope, and actual braking load of wire sample, Company carrying out the test, person carrying out the test and the SWL. Wire ropes that have an end termination (ferrule secured) must be supplied with a valid test certificate, the certificate must also show as a minimum the construction / configuration of the rope, grade of rope, proof load applied, Company carrying out the test, person carrying out the test and the SWL. Boom pennant lines if fitted should be accompanied with the same documentation as ferrule secured wire ropes. Hook Block / Headache Ball Certification, all hook blocks and headache balls must be individually load tested to the requirements of BS 7121. 100% NDT of hook and shank is a requirement at load test. Particular care should be taken to ensure the hook block is fitted with the correct size sheave for the wire rope that is to be fitted.

LIFTING EQUIPMENT CONTROL AND OPERATION PROCEDURE AzSPU MAJOR PROJECTS BP-CDZZZZ-CM-PRO-5001

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Wedge Socket Certification, Wedge sockets will have a test certificate or as a minimum a certificate of conformity. Certificates should state the rope size the socket is designed for and the rated capacity or efficiency. Wedge sockets shall be marked with as a minimum a serial number and SWL or rope size Wedge sockets should have a 100% NDT carried out at the time of the crane inspection. Load Indicators, It is understood that no local organisation can provide calibration of cab based load indicators, for this reason a six monthly verification should be carried out with a calibrated load cell, this task should be carried out by a third party and a certificate issued. Where load indicators are not fitted i.e. overhead cranes, only known weights shall be lifted. If a load indicator is fitted it must be operational. When booms lengths are changed or decreased to increase the SWL on lattice boom cranes, a load test is required as per the overloads in BS 7121 Pt 2 ( Safe use of Cranes ) or ASME 30.5 ( Mobile & Locomotive Cranes) When lattice boom lengths are increased, lowering the capacity of the crane. The crane will not require a load test, however a Company approved procedure must be followed and a verification test must be carried out. All crane mechanical and structural repairs must be carried out inline with the manufactures guidelines or manuals. Mechanical repairs should be carried out by appropriately trained and competent mechanics and where possible manufactures approved parts fitted. Weld repairs must be carried out using the correct materials and approved weld procedures appropriate for the parent material. A positive material identification test should be carried out where there is no positive evidence of the material grade or makeup so that the appropriate weld procedure and consumables can be identified before welding can be carried out. Crane Pre use inspections, all operators must carry out a crane inspection at the start of each shift, this inspection must be recorded. The format must be approved and records made available to Company if required. The maintenance department must gather the records at a suitable time interval ensuring any repairs are carried out in a timely manner. Cranes shall be inspected at intervals not exceeding six months by a third party inspection Company.

3.6 Overhead Cranes Overhead cranes shall be so designed that the stresses do not exceed the allowable as

specified in the relevant standard. Generally, the construction of the building or module in which the crane is to be installed will dictate the cranes maximum capacity.

All the certification requirements listed 3.5 are also applicable Load indicators are not standard fitment on overhead cranes so only known weights can be

lifted.


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3.7 Spreader Beams and Lifting Frames

In view of the different types and styles of such structures, it is considered practicable to state only the basic design and manufacturing requirements. All shall be designed to EN 13001 Part1 & 2 ( 2007 ) or equivalents All Lifting Beams / Spreader Beams are required to be load tested, although a calculation is acceptable to the requirements of LOLER, major projects require a verification of suitability i.e. load test. The Lifting Beams / Spreader Beams should be thoroughly inspected and NDT carried out on welded connections prior to the proof load test, and if satisfactory, shall be tested to the required loads in table1 The load test will be the responsibility of the manufacturer. If a load test is required on site it shall be carried out by an independent third party Company Each unit shall be subject to a Proof Load Test (See Table 1). Table 1 - Proof Load Test for Spreader Beams and Lifting Frames

Safe Working Load of Unit Minimum Proof Load

< 3 tonnes SWL + 100%

> 3 < 6 tonnes SWL + 3 tonnes

> 6 < 20 tonnes SWL + 50%

> 20 < 40 tonnes SWL + 10 tonnes

> 40 tonnes SWL + 25 tonnes

The test load shall be a live load applied to the complete structure. Loading of the individual

lifting points separately is acceptable only in exceptional circumstances. Immediately prior to, and after the application of, the proof load test, all material and welds

associated with the critical lifting points shall be 100% non-destructively tested. Upon completion of the test, only structure, lifting points and associated lifting gear which do

not show any permanent deformation shall be put into use. A Certificate of Test and Examination shall be supplied for each spreader beam or lifting

beam and the Non-destructive Examination (NDE) reports shall also be issued. If available shall also be accompanied by a copy of the approved fabrication drawings and stress calculations.

Each spreader beam or lifting frame shall be inspected by a competent person prior to each

occasion it is used. In addition, each unit shall be thoroughly examined at six-monthly intervals by a competent person who is independent of the Company.


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3.8 Lifting Points

At present there are neither national nor international standards pertinent to the full range of fittings considered as lifting points. Where reference is made in this document to the use and selection of associated lifting gear it will be in accordance with the appropriate Company standards. When practicable, the number of lifting points incorporated in the design should be sufficient to ensure stability, and limit stress in the structure to within design limits. They should also be positioned so that each point supports an equal proportion of the total load. Fabricated lifting points should be designed to withstand transverse bending of the plates and welds. Each lifting point should be designed to have a factor of safety of not less than 4:1, based on the rated load applied vertically, and the ultimate tensile stress of material used. The factor of safety will be 3:1 when the lifting point is a jacking point, and when the lifting force is applied normal to the jacking surface. When calculating the rated load factors, such as weight allowance and dynamic amplification factor, the location of the centre of gravity should be considered. Lifting points should be orientated in such a direction as to minimise out-of-plane loading. Consideration should be given to the number of lifting points which will bear the load at any one time. When lifting points are designed for use with shackles, the dimensions will be such as to accept the pin of the shackle and suit the shackle jaw gap. As a guideline, the hole diameter should equate to the shackle pin diameter plus 10% and the plate width (including cheek plates if required) equate to the jaw gap minus 10%. Tighter tolerances will cause problems especially after the application of a coating to an offshore specification. Lifting points will be designed in accordance with recognised design codes and standards. Welding carried out in the fabrication of lifting points and attachments shall be performed by welders qualified to the appropriate codes and in accordance with Company approved welding procedures and standards. Installation Lifting Points, These are described as lifting points that are purely for installation of an item or equipment and not for continuous or repeated use. This would include welded or cast lifting attachments i.e. padeyes or brackets For loads under 3 te per lifting point, the lifting points will not require a load test but should be designed using the guidance given above and to allow for dynamic factors. For loads over 3 te per lifting point the manufacturer / fabricator shall be asked to provide a calculation for the lifting point to prove its fit for purpose. If no documentation is available a load test may be required as verification of suitability. If any doubt arises as to the suitability of the lifting point a competent person will decide if a load test or modification is required. As additional verification of status lifting points may require NDT at the request of a competent person or Company.


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Lifting points that are clearly for repeated lifting and lowering equipment will be treated as certified lifting equipment and load tested accordingly

3.9 Containers

Freight Containers – (Shipping Containers) Units generally supplied with materials via coastal ports and fitted with ISO corner casting lifting points. As per the British and European standards unit types A,B,C (40’, 30’, 20’) are not designed to be lifted by sling sets, see BS 3951 – 2 section 6.3.1. Units fitted with ISO corner casting lifting points are designed to be lifted with custom built lifting frames so that the load is transmitted vertically via the four main corner posts. Sling sets transmit the load differently and introduce a compressive force on the main corner posts and structure. Units weighing less than 5 Metric Ton’s (Gross / Empty) maybe lifted with a four or five leg sling arrangement with an angle of not less than 30°, if fit for purpose and the original manufactures data plate is intact and the unit has been inspected and marked within the last 30 months by a competent inspector. Units over 5 Metric Ton’s should be lifted with a suitable spreader beam or lifting frame to ensure only vertical loadings are applied on the main structure or a lower twist lock spreader beam arrangement my be used, if fit for purpose and the original manufactures data plate is intact and the unit has been inspected and marked within the last 30 months by a competent inspector. Modifications to freight containers for general yard movements will be discouraged, changing the ISO lifting points for padeyes does not make these units fit for purpose. These units are designed for vertical loading only on the corner posts. Significant modifications will be required if these units are to be used for general movements. All modifications must be approved by the Lifting Technical Authority Stacking of units with corner castings is acceptable if a minimum of two twist locks per container are used, (diagonally). It is accepted that this type of container does not always travel with a certification pack, the Certifying Authority (DNV, Lloyds Register, ABS) always fit data plates ( CSC ) that corresponded to the manufactured batch numbers and information. It is common practice to accept the data plate information as verification of the acceptance criteria laid down by the relevant EN standards and certification authorities. Units that are not fitted with manufactures plates should not be lifted until a 3rd party examination or test has been carried out or approval is given by the Lifting Technical Authority. Inspection periods shall be no longer than 30 months for in service units and any unit that’s out with this date and will be moved / lifted shall be examined prior to lifting by a competent 3rd party examiner. Records of examinations of these units shall be kept with the Site Controller and a register detailing the location and the next examination due dates maintained.


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All Freight Containers must be appropriately checked prior to use. Units for Offshore transportation (CCU’s) must be manufactured to EN 12079, 2006 or DNV2.7.1 standards as a minimum, and inspected every six months. It is important to note that the lifting assembly fitted to CCU’s are deemed to be accessories for lifting and shall therefore be subjected to a 6 monthly thorough examination.

3.10 Man Riding Baskets

Man-riding operations should only take place if no other reasonably practicable means can be found to carry out the task. Man-riding operations shall be conducted under the requirements of SSoW AZSPU-HSSE-DOC-00059-2 and in line with the site / installation specific procedure containing a rescue plan and shall state requirements for level 2 risk assessment to be carried out prior to start of any man riding operations..

3.10.1 Man Basket Construction

The following principles or guidelines apply to the construction of all man baskets used on all BP controlled construction sites in Azerbaijan: Passengers must be protected from harm: man baskets should be of sound construction, in good and safe condition, and must be fully enclosed to prevent passengers from falling, being crushed, trapped or struck. In an emergency, passengers should not be exposed to any further danger: should personnel become trapped in a man basket, they should not be exposed to any further danger and they must be capable of being freed. The basket must be protected from falling: fall arrest devices must be in place to prevent the basket falling if the primary means of support fails (this can entail suitably rated ropes with independent anchorages. In the absence of specific design criteria for fabricated man-riding personnel baskets before 2005 ( EN 14502-1 Equipment for Lifting Persons ) as a minimum baskets shall conform with this guidance and certain safety features can be adopted from BS 2830 – which addresses Suspended Work Platforms. As a minimum all man baskets shall have:

• A minimum height from the floor to the underside of the top handrail to prevent persons

toppling over. (Minimum height = 910mm but recommended height of 1150mm preferred).

• A maximum vertical distance between the handrail/intermediate rails to prevent

persons falling through. (Max = 500mm) • A minimum of 4 Lifting points must align to centre of lift • Floors to be slip-proof and must be a minimum area for each person working in the

basket. (Minimum area per person recommended = 600mm x 600mm)


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• A stipulation that toe boards must be fitted all around the flooring if the basket is open sided. (Minimum depth 150mm.)

• Mesh sides to aid visibility form basket or visibility for crane operator / banks-man • Internal handrails to prevent hands/fingers being trapped if the basket swings against

an obstruction. • Doors (if fitted) must open inwards and have a locking mechanism to prevent

inadvertent opening. Or integral ladder for access/egress • Basket should have internal anchor points for safety harnesses. • The lifting slings, if fitted with a fifth leg (top lifting leg) should have a sixth leg in parallel

as a safety back-up. ( Safety Factor for wire rope slings should be not less then 10:1 ) • It must be marked with a SWL and that it is suitable for man-riding • In addition, it is recommended that the following safety features are incorporated. Note: These are not mandatory but considered good practice/design: • A roof to protect personnel from falling objects. • The base of the basket should have rubber buffers to prevent jarring of the spine when

being landed. • Certification data plate and markings board • The certification for the basket (including slings/shackles etc.) must be current, i.e.: It

must have a proof load test certificate.

• It must have been inspected by a competent person within the previous 6 months

Note: The basket and accessories must also be inspected immediately before each use by a competent person.


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3.10.2 Man Riding Belts and Harnesses

Riding belts are work restraint, work positioning (including abseiling, rope access and positioning techniques), fall arrest or rescue systems. Riding belts can be used only by qualified abseilors, and then if: A risk assessment has demonstrated that work can only, so far as is reasonably practicable, be performed safely while using an abseiling technique The abseiling equipment shall be inspected and certified in accordance with international and manufacturer’s standards and instructions should be checked to consider whether the item is compatible with other equipment being used. The equipment’s safe working loads (or minimum static strength), working load limits or maximum (and sometimes, minimum) rated loads should be checked. Any equipment used for work at height is required to meet relevant European Standards (i.e. it is CE marked and tested to relevant European norms (EN) and all new PPE should be traceable to a certificate of conformity. The equipment should also be marked with a unique identification number so that it can be traced back to its point of origin and any test certificates and examination reports. The need for rapid and effective rescue is particularly important when using abseiling equipment, where a delay may have severe consequences, i.e. when someone is left hanging motionless in a harness after a fall resulting in ‘suspension trauma’ as a result of restricted blood circulation. The time before loss of consciousness can vary from about 6 minutes to 2 hours, depending on physical capability and incident severity. Suitable rescue equipment and competent personnel must be available within the abseiling crew and be on site at all times during the completion of tasks at height.

3.10.3 Forklift Cages / integrated Working platforms

In the absence of specific design criteria for fabricated integrated working platforms guidance on certain safety features can be adopted from the HSE Safety Notice: PM28 December 2005. Platforms for use on the fork arms of a truck shall have fork pockets on their underside that will accommodate the fork arms spaced at the widest practicable distance apart without excessive clearance between the pockets and forks. The locating (i.e. pickup) points on carriage mounted and fork arm mounted working platforms shall be symmetrical about the centre line of the working platform. The dimensions of the platform shall be as small as possible, compatible with the number of persons that it is intended to carry and the work they are likely to undertake. The platform dimension parallel to the fork arms, i.e. forward length of the platform, shall not exceed 2 times the rated load centre distance of the truck. The width of the platform shall not exceed the outside width over the truck load wheels by more than 250mm either side.

A positive locking device shall be included on the platform to retain it on the truck when in use. The floor of the platform shall be of adequate strength, horizontal when attached to the truck


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in its elevated position, slip resistant and designed to prevent the accumulation of liquid. Any openings in mesh floors or between the floor and toe-guards or access gates shall be dimensioned so as to prevent a sphere of 15mm diameter passing through.

A top rail being between 1000mm and 1100mm from the platform floor; and at least one intermediate rail, equally spaced between the top of the toe board and the under side of the top rail A toe-board, having a minimum height of 150mm Suitably sized and positioned handholds shall be fitted within the confines of the working platform. To allow for safe use, e.g. to allow use with gloved hands, it is recommended that there is a gap of 90mm between any handhold and the side of the platform. Other equally effective means of guarding between the top rail and floor, such as infilling with robust wire mesh, panelling and/or safety glazing may be used. Gate access should be provided and shall open inwards, upwards or sideways and return automatically to the closed position. It is strongly recommended that a device is provided that locks the gate automatically and ensures it cannot be opened once the platform is raised. Safety harness anchorages shall be included on the working platform

3.11 Cherry Pickers (MEWP’s)

The terminology for this equipment varies from country to country. Mobile Elevated Work Platforms, Boom Lifts (articulated and telescopic), scissor lifts, cherry pickers etc and can be vehicle-mounted, trailer-mounted or self-propelled According to the UK Health & Safety executive MEWP’s still have one of the highest work related incident rates in the UK, the high mortality and injury rate prompted new requirements and regulations and the need for mandatory safety devices. All MEWP’s made in Europe after 2002 should have all the required load limiting and safety devices fitted and are designed to the EN 280 standard. The self-propelled types are preferred for Major projects sites. MEWP’s shall be no older than 8 years old and preferably of modern design, MEWP’s older than 8 years of age will be removed from site. Further guidance is available from the “Company” Lifting Technical Authority

If MEWP’s are used they must be fitted with as a minimum:

• Machine Levelling device with limit switch. • Driven or controlled from the basket shall be fitted with dead mans pedal. • Device for lowering to ground without power. • Load limiting device. • Anchor points for safety harness. • Emergency stop switch.

Contractor must assess the risks of persons falling from or being thrown from the carrier and take precautions to eliminate or control those risks.


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3.12 Grommets and Cable Laid Slings Grommets and Cable Laid Slings shall be manufactured in accordance with the EN 13414 part 3 standard.

For continuity the SWL of Grommets shall be calculated using the formula within EN 13414 part 3 and not the formula / guidance within PM20 or IMCA guidance.

4 Section “C”

4.1 Introduction

To enhance safety in lifting operations on Company worksites, this section of the document gives guidance on planning, risk assessment and personnel’s competence. Safety in lifting operations is largely dependent on the competence of the personnel involved. At present, personnel from all trades use lifting equipment and accessories to perform tasks of varying complexity. For that reason, it is vitally important to establish that their level of training and / or experience is adequate for them to perform the work safely and efficiently. In addition, there are new international standards of competence which have been created to accurately reflect the type of lifting operations various personnel get involved with. These also restrict the level / type of lifting operations personnel are allowed to perform. Whether the job is routine or complex, the proper level of planning will also identify possible problems in advance and so allow for additional measures to be taken to eliminate the problems. As mentioned, lifting operations vary from simple or routine to complicated and complex in nature and the depth of the risk assessment should reflect this. The majority of day-to-day tasks are routine and relatively simple and the risk can be assessed via the use of a small pocket card which prompts the user to question their own ability to do the job safely. The complicated and complex lifting operation will require the use of a step by step lifting plan and full risk assessment.

4.2 Scope

• To ensure compliance with the new lifting related legislation.

• To inform personnel of their obligations to perform lifting operations safely.

• Promote the use of risk assessments.

• To underline the importance of proper planning.

• To explain the need for levels of competency.

Includes all personnel (staff and Contractors) involved in lifting activities on Company worksites.

4.3 Planning

It is a requirement of international regulations that every lifting operation is competently planned. The lifting operation must also be appropriately supervised and carried out in a safe manner. Guidance on the planning of lifting operations is given below:


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The person planning the operation should have adequate practical and theoretical knowledge and experience of planning lifting operations. The plan will require a step-by-step procedure and each step will have to be risk assessed. The plan should ensure that the lifting equipment remains safe for the range of lifting operations for which the equipment might be used. Where two or more items of lifting equipment are used simultaneously to lift a load a written plan should be drawn up and applied to ensure safety. The degree of planning will vary considerably. It will depend upon the type of lifting equipment to be used and the complexity of the lifting operation for which it will be used. The main factors to be considered when selecting lifting equipment is the load to be lifted, its weight, shape, the centre of gravity of the load and lifting device and the availability of lifting points. Other points to consider for the lifting plan are: 1. Where the load is presently positioned and where it will be positioned after the lifting

operation.

2. How often the lifting equipment will be used to carry out the task.

3. The environment in which the lifting equipment will be used; and

4. The people available and their knowledge, training and experience.

The person carrying out this part of the planning exercise must have appropriate knowledge and expertise.

It may be necessary to use specific equipment for lifting particular types of loads, e.g. spreader beams for unbalanced loads or you may need to use specialist handling equipment in conjunction with fork-lift trucks, e.g. reel-handling attachments if you are handling reels of wire rope or similar loads. Use of specific lifting or handling aids must be planned and assessed for risk.

4.4 Planning of Individual Lifting Operations For routine lifting operations, the planning of each individual lifting operation will be described in the generic, job or task risk assessment issued by the rigging Foreman and will be taken to the worksite and fully defined by the people using the lifting equipment, such as the slinger, the fork-lift truck operator, etc. prior to the work commencing. The person carrying out this part of the planning exercise should have appropriate training knowledge and expertise in job risk assessment or RTC techniques.

An example of a simple plan for routine use of an overhead travelling crane would be:

a) assess the weight of the load.

b) choose the right accessory for lifting, e.g. depending upon the nature and weight of the load and the environment in which it is to be used.

c) check the anticipated path of the load to make sure that it is not obstructed.

d) prepare a suitable place to set down the load.


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e) fit the sling to the load (using an appropriate method of slinging) and make the lift (a trial lift may be necessary to confirm the centre of gravity of the load; tag lines may be necessary to stop the load swinging).

f) release the slings (timber packing or similar may be necessary to prevent trapping of the sling); and

g) clear up. As stated in section 5.1 all lifts shall require planning, for simple and routine lifts this may be using the developed and approved pocket cards or similar

4.5 Risk Assessment

In lifting operations, practically each and every job is different and for safety reasons, they all have to be “risk assessed”. The depth of the risk assessment will increase with the complexity of the job and there are numerous factors to consider during the planning stage e.g.:

1. The weight of the load.

2. Position / height of the centre of gravity.

3. Stability of the load.

4. Size and shape of the load.

5. Protection of load during lift.

6. Availability of dedicated lifting points on the load.

7. Availability of suitable rigging.

8. Protection of rigging against sharp edges.

9. Capacity of the crane / hoisting equipment.

10. Availability of certified anchor points / support steelwork.

11. Available headroom.

12. Route to be travelled.

13. Obstructions.

14. Maximum height the load has to be lifted.

15. Any dynamic factors (including sudden movement of vessel etc).

16. Hazards to other personnel.

17. Number of Banksmen required.

18. Communications.

19. Deck / floor / ground capacity for landing the load.

20. The need for tag lines.

21. Available light.

22. Experience / competence of personnel.

To make sure all factors are considered in the risk assessment, the operative, team or Foreman must use the Risk Assessment procedure and formats. To help in considering the risks it would be valuable to use the step-by-step procedure in the lifting plan as a template


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and address / identify possible hazards in each step listed. The risk assessment combined with the lifting plan will help to identify the skill levels required to carry out the lift safely. The lifting operation plan shows how the lift is to be executed and how risks are mitigated. The information gathered, along with the risks should be incorporated into a library of risk assessments / lifting plans for future reference. The actual risk assessment can be performed by anyone who has been trained in risk assessment techniques and has experience in using the lifting equipment in question. However, it is preferable the person performing the risk assessment has knowledge of or is familiar with the specific lifting operation i.e. a person who has done the job successfully and safely before. Risk assessments may also require input from various other personnel / departments to address any interface problems. To assist with the assessments, rigging and lifting operations have been divided into four categories as follows:

4.6 Lift categories

Routine lifts

Are uncomplicated lifts that are performed on a regular basis utilising fixed, dedicated lifting equipment. Essentially this type of lift consists of routine crane or rigging operations within the yard (e.g. loading plate lines and cutting lines, unloading steel from lorry or trailer, moving items in fabrication shops using plate clamps and slings). Minimum qualification: These lifts can be performed by personnel who have attended a Banksman / Flagman / Slinger course and been involved in such operations for 6 months and / or have been assessed and deemed competent in line with the Company internal standards – Basic level / level 1. Reference material: SSoW AZSPU-HSSE-DOC-00056-2 lifting operations

Planning: The use of generic task risk assessments, toolbox talks and RTC is adequate for this level of lifting operation

Simple lifts Simple lifts are those that involve the use of basic hoisting equipment for a simple lifting operation but not requiring specialist rigging skills. This would involve direct lifting using certified lifting equipment suspended from dedicated lifting points such as pad eyes or runway beams (e.g. an electrician utilising portable lifting gear slung from a dedicated pad eye to lift a motor with specified lifting points). Minimum qualification: These lifts can be performed by personnel who have attended a Banksman / Flagman / Slinger course and been involved in such operations for 6 months and / or have been assessed and deemed competent in line with the Company internal standards – Basic level / level 1. Reference material: SSoW AZSPU-HSSE-DOC-00056-2 lifting operations Planning: The use of generic risk assessment plans and toolbox talks is usually adequate for this level of lifting operation.


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Complicated lifts These lifts are those where difficulty is due to the nature of the load e.g. awkward shape, offset or high centre of gravity, fragile, containing liquids, no provision of lifting attachments / difficult to sling etc. The actual lifting operation / handling of the lift may also be difficult e.g. it may require to be rotated or cross-hauled involving two or more sets of rigging and / or tandem lifting with cranes. Minimum qualification: This type of lift must be performed by experienced Riggers who have attended approved Rigging and Lifting training courses and are suitably experienced for the task to be undertaken. Their competence should be verified by qualified D32 / 33 or A1 skills assessors against the competence criteria for Rigging. Alternatively, these lifts can be performed by personnel who have attended a Rigging and Lifting course and been involved in such operations for 12 months and / or have been assessed and deemed competent in line with the Company internal standards – level 2 / level 3. Reference material: SSoW AZSPU-HSSE-DOC-00056-2 lifting operations plus additional equipment lists, drawings / sketches as required. Planning: A specific, written, risk assessment, plan combined with toolbox talks conducted and lead by the Foreman is required for this level of lifting operation.

Complex lifts

These lifts could be any of the first three categories but with additional hazards e.g. extremely heavy loads, confined spaces, restricted headroom, lifting over unprotected plant or equipment, lifting sub-sea, lifts involving divers, lifts involving floating cranes, etc. i.e. lifting operations or conditions which would merit additional engineering input.

4.7 Minimum Qualifications Minimum qualification: This type of lift must be performed by experienced Riggers who have attended approved Rigging and Lifting training courses and are suitably experienced for the task to be undertaken. Their competence should be verified by qualified D32 / 33 or A1 skills assessors against the competence criteria for Rigging. Alternatively, these lifts can be performed by personnel who have attended a Rigging and Lifting course and been involved in such operations for 12 months and / or have been assessed and deemed competent in line with the Company internal standards – level 1 / level 2 with engineering support as deemed necessary by the Supervisor responsible for the work to be carried out. Planning: A specific, written, risk assessment and mitigation plan combined with toolbox talks, convened and lead by the Lifting Supervisor, is required for this level of lifting operation.


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4.8 Operator or Control Requirements

4.8.1 Mobile Crane Operations

Any mobile crane working at a Company worksite must meet with the minimum requirements specified in Section 3.4 of this procedure.

At the beginning of each shift or working day, the Crane Operator, should carry out routine checks including the following: 1. Check that the automatic safe load indicator is correctly set and / or fitted with the

correct cam-card appropriate to the jib length, or jib and fly-jib lengths and the number of falls of hoist rope.

2. Check that the correct load-radius scale appropriate to the jib (or fly-jib) length is fitted on the visual indicator.

3. Where applicable, check the security of the counterweight or ballasting. Where this is in the form of removable weights, check that the weights fitted correctly correspond to those shown on the counterweight chart for the intended operating conditions.

4. Check the oil level(s), fuel level and lubrication.

5. Check the ropes, and rope terminal fittings and anchorages for obvious damage and wear.

6. Check the condition and inflation pressure(s) of tyres (where applicable).

7. Check that all water is drained from any air reservoirs.

8. Check the jib structure for damage.

9. In the interest of safety and fire prevention, check that the crane cabin is in a tidy condition and free from tins of grease and oil, rags, tools, or materials other than those for which storage provision is made.

10. Check the operating pressures in any air and / or hydraulic system(s).

11. Check the operation of the crane through all motions with particular attention to brakes to ensure that these are operating efficiently.

12. Check the operation of all limit switches or cut-outs (use caution in making the checks in case of non-operation).

The Crane Operator must report any faults found to the appointed and responsible Supervisor in order that he can mobilise any specialist personnel required to carry out repairs. When cranes are working on site, there are special setting up requirements to be fulfilled i.e. i) The location of the crane for setting up in preparation for a lift must be approved by the

appointed / responsible Supervisor. ii) The route the crane has to take to arrive at the setting up site must be approved by the

appointed / responsible Supervisor. The crane operator must also ensure, as far as possible, that there aren’t any underground facilities such as drains, gas mains, or water pipes that might collapse under the loading. Once again, the appointed / responsible Supervisor will advise.


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The operator must exercise care when working near the edges of excavations as the load being transferred through to an outrigger can cause the edge to collapse. The operator must also be aware of potential danger overhead in the form of electrical power cables. The recommended minimum distance to operate from these power cables is 15 metres if the cables are supported by steel towers (pylons) or 9 metres if the cables are supported by wood, concrete or steel poles. If a crane has to work any closer to a cable, then the cable will have to be isolated. It must be remembered however, that cables can swing about in windy conditions, and high voltages can arc across substantial gaps. Ideally the crane operator should be able to see the load all the time but as this is not always possible, he will need someone to guide and signal to him. There will always be a designated banksman/signaller, and more often than not, that person will not be the slinger.

4.8.2 Forklift Truck Operations Any forklift truck working on the Company worksites must meet with the minimum requirements specified below. The forklift truck must have the following documentation available for inspection: 1. Current certificate for roadworthiness (if applicable). 2. Current proof load test certificate (i.e. tested within the last 4 years). 3. Proof load test certificates for the mast lifting roller chains. 4. Proof load test certificates for any attachments. 5. Completed and up-to-date daily / weekly maintenance schedules. The forklift operator must have the following documentation available for inspection: 1. Current and valid driving licence. 2. Certificate of training to the appropriate standard. 3. Proof of competence to operate the particular capacity / type of forklift in question. 4. Certificate of medical fitness. In addition, the operator (whether contracted in with the equipment or employed directly by the Company) must be physically fit and of sufficient stature to be able to operate the machine safely.

Any forklift truck working on a Company worksite must also meet with the minimum requirements specified below.

Only Forklift trucks equipped with the following design features shall be used: 1. Automatic audible warning devices that activate when the FLT moves backwards.

Similar devices for forward movement can be considered. 2. An orange flashing beacon light that is activated when the ignition switch is moved into

the “On” position. 3. Operating lights in full working condition at all times. 4. Rear view mirror(s).


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5. Speed governors (particularly for all-terrain duty). 6. Hour meters or system for measuring operating hours and service intervals. 7. An approved two-point seatbelt with appropriate roll over protection cage. 8. Appropriate decals to be pasted on dashboard / rollover cage covering rollover position

by operator as prescribed by the manufacturer. 9. A Master Battery Isolation Switch. 10. Decal stating “Authorised Operators Only”. When selecting an FLT, consideration needs to be given to: 1. Stability (weight of materials to be handled, outreach required, nature of terrain, etc). 2. The guarding of dangerous parts. 3. Noise generated by the FLT. 4. Operator comfort, protection from the weather and falling objects. 5. Air suspension seating or other suitable sprung seating to protect operator from back

pain or similar injury. Padded or foam rubber seats shall not be permissible. Maintenance shall be in accordance with Manufacturers Standards for: 1. Daily checks. 2. Weekly checks. 3. Prescribed service intervals. Maintenance routines shall cover the condition of brakes, lights, horns, hydraulic systems and tires, and the integrity of the structure and moving parts.

4.8.3 Rigging Loft Control It is advised that personnel must only withdraw lifting equipment from the rigging loft if they are trained and qualified to use it. In the absence of the rigging loft controller, only trained staff can sign out equipment. They must ensure they enter in the log book any lifting equipment removed from the loft and up-date the “T” card board or similar recording system accordingly. When returning any equipment to the rigging loft, make sure it is left in the secure “quarantine” area until such times as the loft controller can re-inspect it prior to re-inclusion into the loft. It is understood that not all equipment will be returned to the rigging loft after every task due to the size of the site and the required logistics to move around the work site. However all equipment should have a pre use inspection before use, the Contractor must design a system that will capture and record equipment that is not returned to the rigging loft and ensure a pre use inspection is carried out before use.


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The Contractor may have his own control system for rigging equipment, if he intends to use this system it must be approved by the BP Lifting Technical Authority All six monthly inspections of lifting equipment shall be carried out by an approved third party inspection Company The Rigging Loft Controller shall have sufficient knowledge and skill to examine and identify defective equipment and shall be responsible for withdrawing it from service, placing it in quarantine to prevent further use and maintaining the records appropriately. All items of lifting equipment will be recorded in the Issue Register as follows: 1. date issued 2. name and Company of personnel taking issue of rigging gear. 3. date returned 4. return inspection comments Lifting appliances such as Tirfors, chainblocks, pullifts, snatchblocks etc. will have their status indicated using the ‘T’ card tracking system operated by the Rigging Loft Controller. The ‘T’ card system shall be divided into sections designated ‘in use’ ‘in stock’ and ‘hold-inspection’. Upon issue the ‘T’ card corresponding to the item number shall be removed from the ‘in stock’ column and placed in the `in use’ column. Upon return of ANY item, the item shall be located in the ‘hold-inspection’ area of the Rigging Loft, and where appropriate the corresponding ‘T’ card placed in the ‘hold-inspection’ column. ALL returned items shall be subjected to inspection prior to acceptance back into the Rigging Loft. Items awaiting inspection will be held in the designated ‘for inspection’ area of the Rigging Loft until such time as they can be inspected by the Rigging Loft Controller. Dependent upon satisfactory inspection of the item, the item will be returned to its allocated storage area, and where appropriate the corresponding ‘T’ card placed in the `in stock’ column. Non-conforming items shall be quarantined in the designated secure hold area of the Rigging Loft and tagged accordingly. Where appropriate the corresponding ‘T’ card shall be placed in the ‘hold-inspection’ column, and only removed from the system when the item has been disposed of or returned to the Mechanical Handling Contractor’s shore base for repair. Items of defective lifting equipment shall be quarantined by means of either individual identification (i.e. ‘HOLD - DO NOT USE’ label) or posted location until returned. The label shall be endorsed on the reverse side with the vendor’s non-conformance report number (NCR No.) They should also have any current colour code painted over in RED. Defective equipment can be identified by anyone but must be reported to the Rigging loft controller. If the defective equipment is in a dangerous condition (and obviously scrap) it should be rendered unusable to prevent any inadvertent use prior to being returned to the rigging loft.


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Should it be expected that the defective equipment may be scrapped or will take extended time to be returned to the work site, replacements should be requested from the Rigging Loft Supplier. Arrangements for returning defective equipment back to the rigging loft should be made via the Rigging Loft Keeper and Lifting Superintendent Certification records for the equipment which has been scrapped shall be endorsed accordingly and retained for 12 months beyond the scrap date to provide traceability.

Rotation of Rigging Loft equipment is essential to ensure that at all times correctly certified equipment is used and that defects and damaged equipment is effectively managed. The Rigging Loft Controller must manage the rotation of the Lofts, or re-certification of equipment, such that equipment that is out of date, not certified or not fit for purpose is never put into service. To ensure that the system for rotation of Lofts / re-certification is robust, the following principles will be adhered to:

• The rigging lofts will be changed out or recertified in a timely manner every six months

before the certification of the equipment expires, i.e. before the six months are up.

• The new loft or third party inspection Company must be on the worksite at least two weeks before the old loft must be recertified. The new loft or inspected equipment and inventory will then be checked on worksite and made ready for the issue of equipment.

• Once the new loft or recertified equipment is cleared for use the colour code boards will

be changed and the old loft will be closed for equipment issue and will only receive returned equipment.

• Upon the change of colour code, lifting equipment will only be issued from the new loft.

The previous colour coded equipment will be gathered and the old colour coded lifting equipment returned to the old loft.

• The original inventory list must be checked off to ensure that all the previous loft

equipment has been returned and taken out of service.

• Outstanding equipment will be identified by number and location and the Rigging Loft Controller will ensure it is found and returned.

4.8.4 Webbing and Round slings

On BP operations sites clear guidance is given within the SSoW for control and planning requirements of webbing and round slings, on construction sites the use of this procedure is often not practical. However Contractor shall control the use of webbing and round slings via a written procedure approved by Company.

This procedure shall illustrate the control from the rigging loft to the task using suitably trained and competent personnel

4.8.5 Man Riding Operations

HSE Guidance for cranes used for man-riding operations


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The following guidance given by the Health and Safety Executive in their Offshore technology Report of September 1996 applies to cranes used for personnel lifting operations as well as for cargo loading and unloading.

i) All winding gear should be equipped with a brake, mechanically operable under

all load conditions. The design braking force should be at least 120% of the braking force required to support the stipulated test overload.

ii) The brake should be automatically applied when the drive is in the ‘off’ or the neutral position. Any change speed gearbox should be of constant mesh type: it should not be possible to change the gear ratio while there is any load on the winch. Clutches or other means of disengaging the drive train are prohibited for this type of operation. Brake action should be progressive in order to avoid sudden dynamic shock. Free fall operations of the hoist or boom motion are not permitted.

iii) The brake should be applied automatically upon failure of the power supply to the motor and / or control device.

iv) A secondary brake should be fitted. The secondary brake should be operable by the driver in an emergency situation involving man-riding operations and arrest all crane motions. The secondary brake should be applied directly at the drum and not through gear boxes, gear trains etc. The brake need only be of a size sufficient for arresting the loading of persons and the basket, together with some dynamic allowance. v) An emergency stop should be fitted that can be operated by the driver in an emergency situation. Operation of the emergency stop should arrest all crane motions by the actuation of the motion brakes. In the event of failure of the prime mover to re-start, it should be possible to recover the load by manual means.

vi) Cranes which are suitable for man-riding duties should be clearly marked ‘Suitable for man-riding duties’ at the crane operator’s control location.

vii) All persons being transported by crane should only be transported in a basket which has been approved for such operations and should be wearing all necessary personal safety equipment. They should only be transported from or to vessels when it is considered by the appropriate management personnel that the sea state is such that the operation is safe.

AZSPU-HSSE-DOC-00059-2 contains full details on the crane requirements, work permit, rescue plans, PPE and operational requirements for carrying out man riding operations within the AZSPU. Man-riding in work baskets using cranes, forklifts or winches is usually only carried out as a last resort. Normally, access to an elevated worksite would be provided by a permanent work platform with a ladder or stairway, Cherry Pickers or temporary scaffolding. Only when these are not a viable option, will man riding be considered. Obviously, due to the hazards involved, a vigorous risk assessment would be carried out and special additional safety features would have to be in place such a secondary brakes on hoisting equipment before it could be used for lifting personnel. In addition, all equipment involved in the man-riding operation shall have been inspected by a competent third party inspector within the previous


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6 months. Personnel transfer is also governed by stricter controls and you would not be asked to be a passenger or transferee without receiving training before hand. Section 3.10 of this document contains in-depth guidance which addresses the minimum design requirements for fabricated man-riding baskets. The guidance is based on typical Specifications for suspended access equipment (suspended chairs, traditional steeplejack’s seats, work cages, cradles and platforms). This section also gives guidance, on the safe use of such man-riding baskets, Due to the hazardous nature of man-riding operations, there are a lot of safety checks to be carried out prior to the operation commencing. Refer to the checklist overleaf for guidance.

Further guidance for man-riding and personnel transfer operations can be found in AZSPU-HSSE-DOC-00059-2 Remember, if there is an alternative, feasible method of carrying out the task, use it!


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4.9 PRE MAN-RIDING CHECKLIST Man-riding Task: Date: # All persons involved in the man-riding operation are to be involved in the

completion of the checklist YES NO

1 Have the reasons for man-riding and job objectives been adequately explained to you? 2 Have you reviewed the Risk Assessment and the Rig Specific Procedure for Man-

riding?

3 Are the current environmental conditions suitable for performing Man-riding Activities? 4 Have you attended a pre-job meeting / toolbox talk with all the people involved? 5 Have you created / reviewed the rescue plan and examined the associated equipment? 6 Has the relevant Permit to Work been raised (if applicable)? 7 Have all control measures been implemented? 8 Have all other planned activities that may interfere with man-riding been stopped? 9 Have 'DO NOT USE' warning signs been placed on any other machinery which may

interfere with / compromise the safety of the operation (machinery isolated if possible)?

10 If 'over the side' working is possible has a standby boat been notified? 11 Have the hand signals for RAISE, STOP and LOWER been agreed by all involved? 12 Has the winch operator agreed the principle of 'NO SIGNAL = NO MOVEMENT'? 13 If using Radios - have the RAISE, STOP and LOWER commands been agreed with by

all involved?

14 Have the radios been checked and tested, using a dedicated channel? 15 Is the harness, Karabiner / shackle and winch line ferrule certification in date, clean and

all in good condition?

16 Has the harness been adjusted properly, and is the rider wearing a helmet chin strap? 17 Is the winch line connected directly to the harness? (i.e. no swivels or hooks) 18 Is the winch marked 'MAN-RIDING WINCH' and is the winch certification in date? 19 Is the winch wire in good condition, and spooled correctly? (min 5 turns on drum,) 20 Where possible, have obstructions to vertical travel been removed or tied back? 21 Are the manual and automatic brakes operating correctly? 22 Is the control lever clearly marked, and does it return to neutral on release? 23 Has the emergency stop facility been tested? 24 If fitted, has the load limiter been overload tested? 25 If a fall arrestor (inertia reel) is to be used, has it been tested before use, and does it

have a separate means of connection to the harness? (Note: safety hooks are not permitted)

26 Is the winch operator aware that he must not leave the winch while the person is man-riding?

27 Are the hand tools of sufficient size for easy handling? 28 Are the hand tools tied off to the harness / rider securely? 29 Have the rider's pockets been emptied of loose articles (especially money and other

small metal objects)?

30 Has the equipment been properly demobilised (cleaned, inspected, correctly stored)? You must answer ‘YES’ to all the above and / or qualify any ‘NO’ answer before

commencing with the man-riding operation.

Comments Signature Company Date


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BP-CDZZZZ-CM-PRO-5001 - C2

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