Document Owner: VP Occupational and Process Safety ... Safety...Voltage (Nominal, kV, Alternating...

Valero CTEMS Document

2.2.1 Crane Standard

Final DRAFT

Revision Date: 8/24/2011

Valero CTEMS Standard of 25

Document Owner: VP Occupational and Process Safety Document Type: Standard 1.0 PURPOSE

The purpose of the Crane Standard is to ensure that Valero facilities establish systems to minimize incidents during crane lifting operations.

2.0 SCOPE This performance standard establishes the minimum expectations for Valero facilities and their contractors that perform crane lift operations. This performance standard is intended to cover all mobile and fixed cranes. Types of cranes covered by this performance standard include:

Industrial cranes

Crawler and carrier (truck) mounted lattice boom cranes

Crawler and carrier (truck) mounted telescopic boom cranes

Truck-mounted cranes

Rough terrain/all terrain cranes

Mobile tower cranes

Mobile cranes

Carry decks

Boom trucks

Pedestal cranes

Dock cranes

Overhead/Gantry cranes

Suspended personnel platform (man-basket) use and requirements are also covered in this performance standard.

3.0 REQUIREMENTS Lifting equipment, activities and conditions covered by this performance standard include:

Operator Training and Qualification/Certification

Inspection Testing and Maintenance

Lift Process Requirements

Work in Close Proximity to Power Lines

Soil/Surface, Underground Piping and Utilities

Crane Movement

Crane Lifting and Rigging Practices

Weather Conditions

CARE Cards Each Valero facility where crane operations occur shall establish a written program consistent with the minimum requirements of this performance standard. Facilities may implement more stringent requirements as determined by the facility management. Valero facilities shall comply with all federal, state, province, local regulations, manufacturer’s procedures and national consensus guidelines. 3.1 Operator/Rigger Training and Qualification/Certification Requirements

3.1.1 Valero facilities that own and/or operate cranes shall establish minimum qualifications and training

programs that meet the requirements for operators, riggers, signal persons and maintenance/repair workers. Certifications of personnel shall comply with federal, province, state and local requirements.

Valero CTEMS Standard 2.2.1 Crane Standard

of 25

Mobile crane operators shall be qualified or certified to operate mobile lifting equipment by a recognized and accredited crane/derrick operator testing organization. (i.e. National Commission for the Certification of Crane Operators - NCCCO and National Center for Construction Education and Research - NCCER).

Mobile Crane Operator Certification Programs shall be accredited by the American National Standards Institute (ANSI), the National Commission for Certifying Agencies (NCCA) or the Canadian equivalent agency.

3.1.2 Crane operators working with permanently installed pedestal, dock, overhead and gantry cranes

shall:

Be qualified or certified by the manufacture or company’s designated competent person to operate the equipment.

Follow required training requirements for operating cranes on water ways (i.e. third party training).

Complete refresher training every 5 years.

3.1.3 Riggers and signal persons shall:

Be trained and qualified in the job tasks to be performed. (See Appendix F)

Receive refresher training every 5 years (including ASME B-30.5 Standard Hand Signals). 3.2 Inspection, Testing and Maintenance

3.2.1 Valero facilities that own/operate cranes or other lifting equipment covered by this performance standard shall establish a written inspection, testing and maintenance program for cranes, rigging and personnel platforms. (See Appendix A & C)

When bringing a crane on the site, a qualified Valero Heavy Equipment Operator (HEO) or designee shall conduct a pre-use inspection on the crane.

Cranes or lifting equipment shall have the required inspection and testing certificates current and available prior to or upon arrival.

A Valero HEO or designee shall verify that the crane operator(s) has the appropriate documentation prior to entering the site. Including:

3.2.1.1 Valid Identification Card 3.2.1.2 Experience / Training documentation 3.2.1.3 Crane Operator certification 3.2.1.4 Inspection documentation

Crane owners/operators are responsible to perform crane inspections daily, monthly, annually, or when modification or repairs are made. Documented inspections shall be performed in accordance with federal, state, province, local regulations (OSHA, ASME and CSA).

3.3 Lift Requirements

Valero facilities shall establish processes to ensure all requirements are followed for lifts meeting the criteria of a standard or critical lift. Critical lifts that meet the definition of a super lift shall use (CTEM 2.2.1 Lift Execution Plan - Super Lifts).

3.3.1 Crane loading criteria

Select a crane using the manufacturer’s crane capacity load chart based on the load to be handled, the work radius and boom length.

http://www.encana.com/


of 25

Load weight shall be verified through proper documentation and kept with the crane until the lift is completed.

The total (gross) load weight includes the load to be lifted, rigging, hook-block and auxiliary devices listed by the manufacturer, load handling devices and the product or material that may be contained within the item to be hoisted.

3.3.2 Written lift plans and rigging diagrams shall be developed and used for the following:

Lifts that meet the definition of critical lifts. (See 5.0 Definitions)

Use of suspended personnel baskets. (Appendix D)

Lifts that meet the definition of a standard lift shall use the CARE Card to evaluate and document the lift. (See 3.10 CARE Card)

3.3.3 Minimum criteria for lift plans include:

Crane position for most favorable operating radius, counterweight clearance, boom length, boom clearance and required boom height.

Dimension, weight, center of gravity and configuration of object to be lifted.

Lateral and overhead clearance needed for the lift.

Load restrictions on floors, structures and access roads.

Soil condition and requirements for mats and cribbing. (see Section 3.5)

Impact on underground structures which may be damaged.

Identify one person responsible for: 3.3.2.1 Execution of the lift plan 3.3.2.2 Analyzing the operation 3.3.2.3 Instructing all personnel involved 3.3.2.4 Proper positioning/rigging of the load 3.3.2.5 Crane movements

3.3.4 For critical lift plans, site management shall determine:

When a critical lift plan requires management approval.

When a critical lift plan requires an engineering review by a qualified engineer.

When a detailed hazard assessment is required to be performed by involved parties (Operations, Maintenance, Safety, Project Engineering and Contractors).

3.4 Proximity to Power Lines Valero facilities shall establish processes to ensure all requirements for working in close proximity to electrical power lines are followed. Before beginning equipment operations, the work zone shall be identified by either:

3.4.1 Demarcating boundaries and prohibiting the operator from operating the equipment past those boundaries or

3.4.2 Defining the work zone as the area 360 degrees around the equipment, up to the equipment’s maximum working radius.



of 25

When any part of the crane or load could come within 20 feet of energized power lines whether insulated or un-insulated the site shall follow the requirements below. (For voltages over 350kv refer to 3.4.2.2 Minimum Distance Requirement according to OSHA 1926.1408 Table A – Minimum Clearance Distances.)

3.4.3 Option 1: De-energize and ground the power line – Contact Valero’s electrical department to

evaluate the site, determine the level of voltage and if de-energizing the equipment or line is possible.

3.4.4 Option 2: Follow the 20 foot clearance rule or the Table A minimum distance requirements in 3.4.2.2 and:

Evaluate alternate areas for performing the lift.

Conduct a planning meeting between operations, maintenance and contractors working in the area of the lift to review the job scope, how the work will be performed, actions that need to take place if contact is made with the power lines and if the line can be re-energized.

Follow the grounding requirements of lifting equipment.

Tag line shall be non-conductive.

Use elevated, high visibility markings, barricades or warning lines.

3.4.2.1 If the operator is not able to see the warning line, then a spotter must be used in combination with one of the options: proximity device, warning device, range limiter or insulating link device.

Use a proximity device, warning device, range limiter, insulating link device, or a dedicated person (i.e. spotter). The spotter shall:

3.4.2.2 Be positioned to effectively gauge the clearance distance from the power line. 3.4.2.3 Use equipment that enables direct communication with the operator. 3.4.2.4 Give timely information to the operator to maintain the clearance distance requirement. 3.4.2.5 Have different responsibilities than a signal person.

3.4.5 Radios will be required at all remote locations where phones or other means of emergency communications are not available Radios shall operate on a clear channel (no other interfering communications)

3.4.6 Minimum Distance Requirement according to OSHA 1926.1408 (Table A – Minimum Clearance Distances) when working around energized power lines.

Voltage (Nominal, kV, Alternating Current Minimum Clearance Distance (feet)

Up to 50 kV 10

Over 50 to 200 15

Over 200 to 350 20

Over 350 to 500 25

Exceptions to the Table A clearances may be approved by the Site Safety and Electrical Department. The site shall follow the requirements in 1926.1410 for equipment operations closer than the Table A minimum clearance zones.

3.4.7 When in transit (with no load and the boom fully lowered) follow the OSHA1926.1411 (Table T – Minimum Clearance Distances While Travelling With No Load).

Voltage (Nominal, kV, Alternating Current Minimum Clearance Distance (feet)

Up to .75 4

Over .75 to 50 6



of 25

Over 50 to 345 10

Over 345 to 750 16

Over 750 to 1000 20

Over 1000 As established by the utility owner/operator or registered professional engineer who is a qualified

person with respect to electrical power transmission and distribution.

3.5 Soil/Surface Conditions, Piping and Utilities Protection

3.5.1 Visually inspect the work area for obvious problems (undermining, poorly compacted soil,

unreinforced or damaged concrete, recent underground work in area, underground structures such as sumps, drains, etc).

3.5.2 Underground structures/installations must be considered before travelling and setting up a crane.

Check for potential underground hazards including:

Existence of process and utility piping

Sewer lines

Electrical/communication conduit(s)

Underground piping (especially cooling and fire water lines)

3.5.3 Evaluate load conditions to determine if weight imposed by the total lift will damage piping. Subsurface prints and drawings of the work area may be used as references for such hazards.

3.5.4 Matting/padding size shall be determined based on soil conditions, allowable soil loading, crane size,

type, configuration, total load weight and bearing pressures generated on underground structures. 3.5.5 If soil stability or bearing capacity is questionable, a geotechnical analysis should be completed.

This analysis shall be performed and approved by a professional engineer (PE)

3.6 Crane Movement

3.6.1 Cranes shall have a dedicated spotter and the required permit(s) while maneuvering in the following

areas:

Inside or on tank dikes.

On all docks.

Inside of battery limits of a process unit.

Designated site roadways or other restricted areas.

3.6.2 The spotter and the driver shall evaluate the path of travel for hazards and discuss limitations of the equipment (turning radius, center of gravity, braking system, obstacles, soil conditions, etc.) and identify any areas of specific concern. (Example: CARE Card)

3.6.3 Mobile cranes in transit shall when possible restrain the headache ball or load from swinging freely.

3.6.4 Clearance distances to overhead structures and power lines shall be identified and clearly marked.

3.7 Crane Practices



of 25

3.7.1 Night Time Operations require:

Sufficient lighting (crane operator must consider cab glare during night lifts).

Adequate manpower to direct all aspects of the lift.

3.7.2 Blind Lifts When the crane operator will not be able to see the load and/or the signal person at anytime during a lift or when the crane operator’s vision is compromised, a plan must be developed which addresses the hazards of blind lifting such as:

Establishing an appropriate communication system between signal person and crane operator. Positioning the crane to ensure load/boom or counterweight does not make contact with any

equipment or structure.

3.7.3 Rated Capacities Lifts should not exceed 95% of the crane capacity. Lifts that may exceed the 95% of the crane capacity shall be reviewed and require approval by the site management team.

Reoccurring lifts that exceed the 95% of the crane capacity shall be revaluated to perform the work without exceeding the limit.

3.7.4 Barricades/Exclusion Areas

Lift radius will be barricaded to prevent access by personnel not involved in the lift. The size and configuration of the load will be considered when identifying the area to be barricaded.

Accessible areas within the swing radius of the rotating superstructure of the crane shall be barricaded in such a manner as to prevent personnel from being struck or crushed by the crane. (Example: Danger tape on outriggers)

Other hoisting equipment (below the hook lifting devices) used to hoist materials will have a designated area barricaded while the load is being raised and lowered.

Lifts shall not be performed when workers are under a suspended load.

During outrigger movement, visual contact of the outriggers shall be made by the crane operator or an assigned signal person. All personnel shall be clear of the outriggers during extension and retraction movement.

3.7.5 Load Movement

Hand signals and/or radios with designated channels shall be used for all lifts.

Only one person shall give signals to the crane operator. Exception: Anyone who becomes aware of a safety problem must alert the operator or signal person by giving the stop or emergency stop signal.

Hand signals to the crane operator shall be compliant with ASME B30.5. A copy of the standard hand signals shall be located on the outside of the crane.

Identify the designated signal person and rigger before lifting begins.

Tag lines will be used for control unless they create a greater hazard.

Steps shall be taken to prevent crane or load contact with process equipment/piping.

Lift slowly to avoid shock loading the crane, rigging or load.

3.7.6 Equipment Requirements

All mobile cranes with a maximum rated load capacity 3 tons or greater shall have a functional anti-two blocking (ATB) device. The device prevents contact between the load block and overhaul ball and boom tip.



of 25

All mobile cranes with a maximum rated load capacity 3 tons or greater shall have a functional load indicator, load moment (rated capacity) indicator or load moment (rated capacity) limiter.

Cranes operating with a live boom controlled by a foot brake are prohibited.

Cranes operating with free fall hoist lines are prohibited except when used for pile driving or drilling operations. Pile driving and drilling operation requirements shall be reviewed by the lift supervisor and in accordance with all applicable local, state, province and federal requirements.

Side loading of booms shall be limited to freely suspended loads. Cranes shall not be used for dragging loads at any time or for pushing equipment. The capacity of the crane and its manufacturing limitations must be fully understood.

3.7.7 Rigging Equipment

Spreader bars or any specialty item used to make a lift must be a manufactured design or have been evaluated and approved by a professional engineer. Documentation is required.

Skid boxes (skip pans) shall have the load ratings posted on the equipment. Inspection of the rigging shall comply with this standard.

3.7.8 Points of Attachment (Lifting lugs, trunions, pad eyes etc)

Visually inspect all points of attachments. Report structural deficiencies to supervision.

An inspection report shall verify the structural integrity of the points of attachment for critical lifts and for routine lifts if structural deficiencies are noted.

A qualified engineer shall calculate a safe load limit for points of attachment with unknown capacities prior to using for a lift.

New equipment shall have drawings confirming the ratings and capacities of all points of attachment. A qualified engineer shall design all points of attachment.

Check the load for balance immediately upon placing a strain on the cables or slings.

3.8 Weather Conditions

Valero facilities shall establish procedures for evaluating and communicating the local weather conditions. 3.8.1 The potential for severe weather shall be reviewed in the lift plan/CARE Card for lifting activities both

during the planning and execution of a lift.

Severe weather includes high wind, heavy fog, rain, sleet, snow or ice and lightning.

Lightning strikes within 10 miles of crane operations require re-assessment of personnel safety.

3.8.2 Lifting activities shall be discontinued on indication of dangerous weather conditions or other impending danger.

3.8.3 Reassess lifting activities whenever conditions change and have not been accounted for in the lift

plan/CARE Card.

3.8.4 Always follow the crane manufacturer’s requirements concerning maximum permissible wind speed and how to de-rate the crane under windy conditions. Suspend crane lifting activities when the crane or load is subjected to 25 mph (40km/h) or higher wind speed. Contact the Valero Site Lift Supervisor to evaluate and document if the lifting activities can safely be performed.

3.8.5 The following should be considered when faced with windy or severe weather conditions:

Geometry and shape of the load

Height of the boom and load

Backward stability



of 25

Wind direction on the crane and load (side loading of boom)

Wind tunnel effects possible when operating a crane between structures

Additional loading caused by ice or snow accumulations

3.9 CARE Card

3.9.1 A Crane and Rigging Evaluation Card (CARE Card) or site equivalent form is required to be completed prior to any lift (See Appendix E) that meets or exceeds 50% of its capacity.

If a crane is stationary (doesn’t reset and move around) and a CARE Card is completed for the heaviest lift during the shift, then only one CARE Card needs to be completed.

If multiple repetitive lifts are made without relocating or for moving similar equipment (i.e. transporting six/twelve packs) only one CARE Card is needed.

The CARE Card shall stay with the crane throughout the duration of the shift/job. All CARE Cards shall be returned at end of shift to the supervisor for retention.

Sites shall determine where CARE Cards are exempted (i.e. maintenance shops…) or mandatory.

New crane operators or riggers can review and sign existing CARE Card or use a new CARE

Card. New shift requires new CARE card.

3.9.2 The CARE Card requires the crane operator to identify the requirements for the lift. If the CARE Card indicates a critical lift or if the lift has been determined to be a critical or super lift and appropriate documentation has been completed, the CARE Card is not required.

3.9.3 CARE Cards shall be reviewed and signed by the crane operator and the rigger. Field auditing of

CARE Cards shall be performed by the crane operator’s supervisor/designee on a routine basis. Their signatures will be recorded on the CARE Card. Sites shall determine the number of field and paper audits.

3.9.4 All contractors shall use the Valero site CARE Card unless the site safety and maintenance departments determine that contractor’s CARE Cards meet or exceed Valero’s.

4.0 ROLES AND RESPONSIBILITES 4.1 Valero Facility Management

4.1.1 Each Valero facility shall establish and implement a written crane safety procedure consistent with

the requirements of this performance standard.

4.1.2 Develop a crane safety lift management system.

4.1.3 Require and confirm that key personnel, including contractors, know and understand their roles and responsibilities required by all applicable federal, state, province, local regulations as well as national consensus standards.

4.1.4 Identify roles and responsibilities for the following relative to ASME 30.5-2007:

Site Supervisor



of 25

Lift Director

Crane Operator

Crane Owner or Contractor Lessee

Rigger (Designated Person)

Signal Person

4.1.5 Require and confirm that project managers, crane owner/users and crane operators have the level of authority appropriate for their responsibilities.

4.1.6 Establish a process for critical lift plans to be reviewed and approved.

4.2 Valero HSE Responsibilities

4.2.1 Promote sharing of HSE best practices between facilities.

4.2.2 Review HSE performance measures, perform audits to verify compliance and provide feedback to facilities.

4.2.3 Support incident investigations and tracking of corrective action items

5.0 DEFINITIONS Anti-Two Block Device – a device that, when activated, disengages all crane functions where continued application of power can cause failure of the hoist rope of other component. Competent Person – one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to workers and who has authorization to take prompt corrective measures to eliminate them. Critical Lift – A lift identified as critical or “high risk” using any of the following criteria:

The known total load represents more than 80% of the manufacturer’s rating chart at the working radius (if the total load weight is estimated, the estimate should be conservative); or

The total load is greater than 25 tons (50,000 pounds) over live process equipment or where lifting equipment can impact live process equipment; or

The total load is greater than 50 tons (100,000 pounds) that would not affect live process equipment; or

Two or more cranes are required to work in unison – in proximity to process equipment, offices, or electrical equipment; or

Any part of the lifting equipment or load could be within a high voltage substation, or encroach energized power lines within the minimum distance requirements according to OSHA 1926.1408 (Table A – Minimum Clearance Distances); or

Use of suspended personnel platforms (“man-baskets”) (See Appendix D)

As determined by the site qualified person based on an assessment of the hazards and risks. Lifts over critical process equipment or in high risk hazardous areas or lifts that require special rigging or non-routine crane configuration or where ground stability may be in question may be considered critical lifts by the site qualified person.



of 25

Hydrofluoric Acid - Lifts over operating Hydrofluoric Acid (HF) Alky Units will be reviewed to determine if they meet the requirements of a critical lift based upon the critical lift definitions and location of the lift relative to in service equipment containing HF acid. Critical Lifts shall include a consequence analysis, a review of alternate lifting schemes and contingency plans. Site specific notification requirements for lifts over HF Alky Units may apply (State requirements).

Individual Valero sites may choose to use a more conservative definition based on the process specific risks, contractor experience and frequency of crane lift operations at the site. Critical Refinery Equipment – Equipment identified by each site that has the potential of causing significant operational impacts if damaged or shut down. Qualified Person – person who, by possession of a recognized degree, certificate, or professional standings, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project. Standard Lift – A lift identified as “standard” or “routine” with generally lower risk using any of the following criteria:

The known total load represents less than 80% of the manufacturer’s rating chart at the working radius (if the total load weight is estimated, the estimate should be conservative); or

The total load is less than or equal to 25 tons (50,000 pounds) over live process equipment or where lifting equipment can impact live process equipment; or

The total load is less than or equal to 50 tons (100,000 pounds) that would not affect live process equipment; or

CARE Cards shall be completed prior to lift (trigger for critical lifts).

Super Lift – A critical lift identified as a super lift using any of the following criteria:

Cranes with a greater than or equal to 1,000 ton (2,000,000 pound) capacity; or

Cranes with a less than or equal to 1,000 ton (2,000,000 pound) capacity shall be evaluated to determine if the super lift criteria will be applied (i.e. complexity of the lift, size and complexity of crane, unique/non-standard cranes, chart capacity, clearance, change in standard crane configuration by adding counterweights or trays)

See (CTEM 2.2.1 Crane Standard – Super Lifts)

Two Blocking – The condition in which the upper most component on the hoist line comes in contact with the boom tip, fixed block or similar component

6.0 PERFORMANCE MEASUREMENT

6.1 Performance Measurements

6.1.1 Compliance with this standard will be measured using reports generated in IMPACT. Each site is

required to report/record incidents, near misses and occasions where the corporate standard and/or site specific procedures were not followed.

6.2 Assessment



of 25

6.2.1 Each site will conduct audits on the standard’s requirements and track their corrective actions as part of the site hazard recognition program.

Minimum – Monthly random audits.

6.2.2 Biannually, each site will assess and document their site specific procedures and practices including:

Incident reviews.

Audit reviews and findings.

6.2.3 Corporate Health, Safety and Environmental (HSE) assessments will be conducted as determined by the corporate audit schedule with a minimum frequency of every three years.

7.0 MANAGEMENT REVIEW The CTEMS Standard Owner shall review the results of the assessments conducted per section 6.0 of this standard annually and shall make revisions as appropriate to achieve desired business results.

8.0 REFERENCES AND LINKAGES The following references should be consulted as needed when applying this performance standard. All conflicts, issues, or questions concerning the consistency and application of this performance standard with the regulations should be brought to the attention of Valero Corporate Health and Safety.

ANSI / ASME Standards pertaining to cranes and rigging: B30.2-2005 Overhead and Gantry Cranes B30.3-2004, Construction Tower Cranes B30.4-2003, Portal, Tower, and Pedestal Cranes B30.5-2007, Mobile and Locomotive Cranes B30.5 Proposal for “Critical Lifts” Appendix to B30.5 B30.6-2003, Derricks B30.9-2006, Slings B30.10-2005, Hooks B30.14-2004, Side Boom Tractors B30.20-2006, Below-the-Hook Lifting Devices B30.22-2005, Articulating Boom Cranes B30.23-2005, Personnel Lifting Systems B30.26-2004, Rigging Hardware

API RP 751 (2007) Safe Operation of Hydrofluoric Acid Units

U.S. Department of Labor (DOL), Occupational Safety & Health Administration (OSHA), Regulation (Standards – 29 Code of Federal Regulation (CFR)) Part 1910 Occupational Safety and Health Standards for General Industry

Subpart N – Materials Handling and Storage: §1910.179 Overhead and Gantry Cranes §1910.180 Crawler Locomotive and Truck Cranes §1910.181 Derricks §1910.184 Slings

U.S. DOL, OSHA, Regulation (Standards – 29 CFR) Part 1926 Occupational Safety and Health Regulations for Construction Subpart H – Materials Handling, Storage, Use, and Disposal: §1926.251 Rigging Equipment for Material Handling



of 25

Subpart DD – Cranes and Derricks §1926.1501

Subpart CC – Cranes and Derricks in Construction

§1926.1400

Canadian Standards, Règlement sur la formation professionnelle de la main-d’œuvre dans l'industrie de la construction

R.R.Q.., c. R-20, r.6.2

Dernière modification: 30 octobre 1997

à jour au 4 novembre 2003

9.0 REVISION HISTORY Revision Log

Revision Date

Revision No. Revision Summary

8/24/2011 0 Final Draft for Management Review and Approval

10.0 APPENDICES



of 25

Appendix A

Crane, Rigging and Lifting Equipment IT&M Program

Valero facilities that own/operate cranes or other lifting equipment shall establish a written inspection, testing and maintenance program for cranes and lifting equipment that includes the following:

1. An inventory of lifting equipment to be included within the program, including lifting equipment (cranes, boom trucks, carry decks, etc.) and rigging equipment (slings, shackles, etc.)

2. A system to document the inspection, testing, and maintenance of lifting and rigging equipment.

3. Documented organizational responsibilities and accountabilities for implementing the IT&M program.

4. Written maintenance procedures that follow manufacturer’s requirements as well as recognized and generally accepted good engineering practices.

5. Establish inspection, testing and maintenance frequencies for cranes and lifting equipment consistent with OSHA, ASME, CSA requirements, applicable manufacturer’s recommendations and good engineering practices for the following:

5.1 Crane Daily Inspections

All cranes operating on Valero property will be inspected daily before use by the crane operator. Any unsafe conditions will be corrected before the crane is allowed to operate in any Valero site. Inspections include items identified in OSHA 1926.1400 and ASME B30.5.

5.2 Crane Monthly Inspections

All cranes operating on Valero property will be inspected at the beginning of service and monthly by the site lift supervisor or designee. The Valero site lift supervisor or designee responsible for the execution of the job or project will ensure that inspections are performed and documented. Inspections include items indentified in OSHA 1926.1400 and ASME B30.5.

5.3 Crane Annual Inspections

All cranes operating on Valero property shall receive an annual inspection of the hoisting machinery by a competent person, or by a government or private agency recognized by the U.S. Department of Labor. Inspections include items identified in OSHA 1926.1400 and ASME B30.5.

5.4 Rigging Equipment Inspections

All rigging and associated lifting equipment accessories will be inspected and in compliance with OSHA and ASME.

Legible tags shall be provided for all slings as identified in ASME B30.9.

Documentation of proof tests shall be provided by the manufacturer and retained on file with the owner.

Valero facilities will provide a system for identifying Valero owned equipment and shall use a color coding system to identify quarterly inspections.

Rigging equipment will be kept separate from equipment used for fall protection – Both will have different types of identification markings or tagging.



of 25

Rigging equipment found to be defective shall be removed from service immediately and destroyed by cutting completely through the device.

Note: Contract companies working on Valero property are responsible for completing all inspections before use. The contract company shall be prepared to produce all documentation ensuring inspections were completed. Any Valero employee acting as representative to a contractor is responsible for ensuring that contractors are solely responsible for training and supervising their personnel such that they too understand and comply with Valero’s requirements.



of 25

Appendix B Rigging Diagram & Lifting Plan (Example)

Location _______________________________________________________ Date of Lift __________________________

Load Description _____________________________________________________________________________________

Lift Description _______________________________________________________________________________________

I. General Information

A. WEIGHT (lbs.) lbs

1. Weight Equipment _________ 2. Weight of Headache Ball _________ 3. Weight of Block _________ 4. Weight of Lifting Bar _________ 5. Weight of Sling & Shackles _________ 6. Weight of Jib ( ) Erect ( ) Stored _________ 7. Weight of Headache Ball on Jib _________ 8. Weight of Cable _________ 9. Allowance for Unaccounted Material in Equipment _________ 10. OTHER _________ TOTAL WEIGHT _________

Source of Load Weight: ___________________ Weights Verified by: ___________________ B. JIB

Erected___ Stored___ 1. Does the job require a Jib? ___________________ 2. Length of Jib ___________________ 3. Angle of Jib ___________________ 4. Rated Capacity of Jib from Chart ___________________ C. CRANE PLACEMENT

1. List any Deviation from Smooth Solid Foundation __________________________________________ 2. List any Underground Line __________________________________________ 3. List Electrical Hazards in Area __________________________________________ 4. List Obstacles or obstructions to Lift or Swing __________________________________________ 5. Swing Direction and Degree (Boom Swing) __________________________________________

6. Track, outrigger loading or on rubber __________________________________________

D. CABLE

1. Number of Parts of Cable ___________________ 2. Size of Cable ___________________ E. SIZING OF SLINGS

1. Sling Selection a. Type of Arrangement _______________ b. Number of Slings in Hook-Up _______________

c. Sling Size _______________ d. Sling Length _______________

e. Rated Capacity of Sling _______________ 2. Shackle Selection a. Pin Diameter (Inches) _______________ b. Capacity (Tons) _______________ c. Shackle Attached to Load by _______________ d. Number of Shackles _______________ F. CRANE

1. Type of Crane ____________________ 2. Crane Capacity ____________________

3. Maximum design wind load _____________ MPH 4. Lifting Arrangement a. Max. Distance - Center of load to center pin of crane _______________ b. Length of Boom _______________ c. Angle of Boom at pick-up _______________ d. Angle of Boom at set _______________ e. Rated capacity of crane under severest lifting conditions (from chart) 1. Over Rear _______________ lbs. 2. Over Front _______________ lbs. 3. Over Side _______________ lbs. 4. From Chart-Rated Capacity of Crane for this lift _______________ lbs. 5. Max. Load on Crane __________________ 6. Lift is _____% of Crane's Rated Capacity

G. SOIL EVALUATION RESULTS _________________ _____________________________________________

H. PRE-LIFT CHECK LIST

1. Outrigger Matting Acceptable Yes / No 2. Outriggers Fully Extended Yes / No 3. Outriggers Match Load Chart Yes / No 4. Crane in Good Condition Yes / No 5. Swing Room Yes / No 6. Head Room Checked Yes / No 7. Max. Counterweights Used Yes / No 8. Counterweights Match Load Chart Yes / No

9. Tag Line Used Yes / No 10. Experienced Operator Yes / No 11. Experienced Flagman (designated) Yes / No 12. Experienced Rigger Yes / No 13. Load Chart in Crane Yes / No 14. Counter weight swing barricaded Yes / No 15. Wind Conditions ___________________________ 16. Crane Inspected By: ________________________ 17. Functional Test of Crane by: __________________



of 25

Appendix B (continued) Rigging Diagram & Lifting Plan (Example)

II. Special Instructions & Diagrams (Prepared by support Engineering)

A. Special instructions or restrictions for crane, rigging, lift, etc. B. Crane/Load placement, Lifting Point and Rigging Diagram (use separate sheet if necessary).

C. Contingency plan details

__________________________________________________________________________________________________________________________________________________________ _____________________________________________________________________________

D. Communication system to be utilized __________________________________________________________________________________________________________________________________________________________

III. Authorization

A. Multiple crane lifts require a separate lift plan for each crane.

B. Any changes in the configuration of the crane, placement, rigging, lifting scheme, etc., or changes in any calculations will require a new lift plan.

C. Suspended personnel baskets shall be used when there is no safe alternative means of access to

the work area such as ladder or erection of scaffolding. A pre-lift meeting with all personnel involved in the lift must be held before the trial lift. (See Appendix C)

D. SIGNATURES + _______________________ Heavy Equipment Operator _______________________ Rigger/Equipment Inspector Review _______________________ Safety Department Representative _______________________ Maintenance Foreman or Supervisor _______________________ Operations Shift Superintendent or Shift Foreman + Authorization can be given by a designee when specified approver is unavailable. Authorization is voided if crane is relocated.



of 25

Appendix C

1. Use of Suspended Personnel Baskets 1.1 When the erection or use of conventional means of reaching the work site (e.g. ladder, stairway,

scaffolding, etc.) would be more hazardous or is not possible because of structural design, a suspended personnel basket can be used.

Note: Written justification for use of a suspended personnel basket is required. The justification must include an evaluation confirming that the erection, use and dismantling of convention means of reaching the worksite, such as a ladder, stairway, aerial lift or scaffold, would be more hazardous or is not possible because of structural design or worksite conditions. Authorization for using suspended personnel basket must be obtained before use. (See Appendix D)

Note: A meeting shall be held prior to the trial lift with all personnel involved. All aspects of the lift must be discussed.

2. Personnel Basket Requirements 2.1 Personnel baskets must meet or exceed the applicable local, state, province and federal requirements.

2.2 The design of the basket must support at least five times the maximum intended load. A plate clearly

displaying the platform's weight and rated load capacity must be clearly displayed, and this loading capacity may not be exceeded at any time.

2.3 The basket will have a standard guardrail system, toe board, and midrail. It must also have a grab rail.

2.4 It must have overhead protection if there are overhead hazards.

2.5 If an access gate is provided, it must have a restraining device to prevent accidental opening during hoisting. Recommended practice is an access gate that swings inward.

2.6 The basket must be secured prior to personnel entering or exiting. The crane load and boom hoist

drum brakes, swing brakes and locking devices must be engaged. No lifts may be made on any of the crane's other load lines during personnel basket use.

2.7 Personnel baskets shall be used only for personnel, their tools and the materials necessary to do their

work. Baskets shall not be used to hoists materials or tools when not hoisting personnel.

2.8 Personnel must keep all body parts within the basket while in motion and must be wearing a body harness. Personnel exiting the basket at elevated locations shall maintain 100% tie off.

2.9 A qualified person in accordance with the manufacturer requirements shall inspect personnel baskets

annually.

2.10 All personnel working in or lifting a personnel basket shall be trained on the use, operation, inspection and rigging of the basket. A qualified signal person shall be inside of the basket. No one shall work alone from a basket.

3. Rigging

3.1 When using wire rope bridle to connect the personnel basket to the load line, connect each bridle leg with a master link or shackle to ensure even distribution of the load.



of 25

3.2 The main hoist block or whip line must have a hook that can be positively locked closed.

3.3 A backup safety choker, no less than 5/8” diameter must be attached to the master link and secured to the lifting blocks above the hook. In the case of a whip line, the safety cable is shackled directly to the whip line above the ball. For the main hoist block, the safety cable can be passed above through the hook mounting plate or shackled directly to the dead end ear or hole, or to the standing becket line on block with and odd number of running parts.

3.4 Wire rope, shackles, rings, master links and other rigging hardware must be capable of supporting, at

least five times the maximum intended load. Shackles, if used in the suspension system, shall be of a bolt type with cotter pin.

3.5 All eyes in wire rope slings shall be fabricated with thimbles.

3.6 Multiple part blocks for suspend personnel basket lifting does not allow for a place to attach the safety

cable. Multiple reeve blocks should be avoided.

3.7 When performing hot work (welding/burning) from a personnel basket, provide suitable electrode holders to protect them from contact with any conducting components of the basket.

3.8 When performing fresh air work from a personnel basket, a minimum of two workers must be in fresh

air to perform the work.

4. Inspections and Trial Lifts

4.1 Immediately prior to using the basket, a trial lift of the unoccupied basket loaded to at least 125% of the basket capacity shall be made from ground level, or any other location where employees will enter the basket, to each location of which the personnel basket is to be hoisted and positioned.

4.2 Prior to hoisting personnel, a trial lift shall be repeated whenever the crane is moved and set up in a new location.

4.3 After the trial lift, prior to hoisting personnel, the basket shall be hoisted a few inches and inspected to ensure that it is secure and properly balanced. The following items shall be inspected:

Hoist ropes shall be free of kinks.

Multiple part lines shall not be twisted around each other.

Center the primary attachment over the platform.

Ensure proper sealing of all wire ropes on drums and in sheaves.

4.4 A competent person who is trained and qualified in the safe use of cranes, shall perform a visual inspection of the crane, rigging, platform and the crane base support on ground to determine whether the testing has exposed any defect or produced any adverse effect upon any component or structure.

4.5 Correct any defects found during inspections before hoisting personnel.

5. Operational Criteria

5.1 Hoist personnel baskets in a slow controlled and cautious manner using a ground person and tag line when required. The load line hoist drum brake must have a system on the power train (other than load hoist brake) that regulates the lowering speed.

5.2 Engage all load and boom hoist drum brakes, swing brakes and locking devices such as pawls or dogs

when the occupied personnel platform is stationary.



of 25

5.3 Cranes shall be uniformly level within 1% of level grade on firm footing with outriggers in place before

beginning lifting operations or as specified by the manufacturer’s requirements.

5.4 Total weight of the loaded personnel platform and related rigging shall not exceed 50% of the rated capacity for the radius and configuration of the crane.

5.5 Boom angle indicators shall be functional and readily visible to the operator. Cranes with telescoping

booms shall be equipped with a device to indicate the operator and booms extended length at all times.

5.6 A positive acting device must be used which prevents contact between the load block and overhaul

ball and boom tip (Anti - two blocking device).

5.7 The crane operator must remain at the crane controls when the crane is running and the basket occupied. Either the crane operator or signal person must remain in the constant visual or radio communication with personnel in the basket at all times.

Note: Upon indication of any dangerous weather conditions or other impending danger, promptly discontinue hoisting of personnel. Suspend hoisting activities at 20 mph sustained wind speed or per crane or personnel platform manufacturer’s requirements, whichever is less.



of 25

Appendix D

Personnel Lift Plan (Example) 1. JOB DESCRIPTION

Company ____________________________________ Lift Point ______________________________________

Estimated Lift Height ______________ Planned Lift Date(s) _______________ Job Originator _______________

2. LIFT EVALUATION

Based upon the requirement and the evaluation of alternative methods (scaffolding, fixed stairs, ladders, man lift, etc.), the use of a suspended personnel platform is regarded to be less hazardous than the alternatives considered. Written justification must be attached to this form.

Valero Maintenance Management________________________________________ Date _________________

Valero Safety Management______________________________________________ Date ________________

3. EQUIPMENT, INSPECTION AND LOAD CALCULATION

(A) Load Testing Certificate attached

YES NO (B) Anti Two-Block Device Operational YES NO

(C) Locking Device Operational (hook)

YES NO (D) Basket meets requirements YES NO

(E) Proposed Boom Angle: (F) Proposed Length of Boom:

(G) Proposed Lift Radius: (H) Chart Rated Capacity at Radius (attach chart):

(I) Maximum load (H) x ½ = (J) Test Weight Calculations:

The Maximum Load (I) must be greater than Calculated Working Load (J).

(a) Number of Persons x 250 lb __________________

(b) Whip Line Ball Weight ___________________

Comments:



of 25

Calculations Completed by: (c) Basket Weight ___________________

(d) Load Block Weight ___________________

(e) Equipment and Tools ___________________

(f) Auxiliary Deductions ___________________

(g) Equipment and Tools ___________________

(h) Calculated Working Load (a)+(b)+(c)+(d)+(e)+(f) (g) =

________________________________________________

___________________________________________

4. PERSONNEL BASKET INSPECTION CHECKLIST

A. Basket to be equipped with a guardrail system (top and mid rail and toe board) and enclosed construction between the toe board and the mid rail (solid or expanded 1/2” metal).

B. A hand rail installed on the inside of the guardrail system around the platform perimeter.

C. Access gates provided with restraining device to prevent accidental opening.

D. Constructed with enough headroom to allow personnel to stand upright.

E. All rough edges exposed to contact by personnel are surfaced smooth.

F. The platform weight and maximum load capacity shall be posted permanently on the platform.

G. Safety cable attached.

5. TRIAL LIFT, PRE-LIFT MEETING AND FINAL INSPECTION

A Pre-Lift Meeting, unoccupied lift test, final visual inspection of equipment, and occupied trial lift were conducted per the requirements of this Policy and Procedure.

Conducted By: ___________________________________________________ Date Meeting Held: ________________________________________________ Valero Safety Department: __________________________________________ Maintenance Department: ___________________________________________ Crane Operator: _________________________________________________

Appendix E

CARE Card (Example)



of 25

Crane Checklist Valero - Crane Safety

CARE Card (Crane And Rigging Evaluation)

Date:_________ Time:

Equipment to be lifted:____________

______________________________

Area:

Company:

Is this a Critical Lift? Y or N

If this is a Critical Lift, contact the

Valero Heavy Equipment Supervisor.

Crane Operator:

NAME:

SIGNED:

Rigger:

NAME:

SIGNED:

Audited by Supervisor/Designee:

Date:_________ Time:

NAME:_________________________________

SIGNED:

NOTE: This CARE Card does not replace any other checklists, Critical Lift plans, or permits. It is a field tool to enhance safety & communication.

(Circle Response)

1. Lighting Adequate? Y or N

2. Permits Issued for crane? Y or N

3. Barricade erected and tagged

properly? Y or N

4. Swing radius of crane clear? Y or N

5. 100% agreement that the job is

ready to proceed? Y or N

6. Communication established

between rigger and crane operator

(Pre-determined radio channel or

line of sight)? Y or N

Comments:

________________________________

________________________________

________________________________

________________________________

Issues or Recommendations:

Cranes are critical tools for our

everyday work. The responsibility for

the equipment and the safety of all

personnel involved in and around any

lift is under the control of all those

involved. The Operator and Rigger

will fill out all items and sign the Care

Card. The supervisor or designee will

audit Care cards in the field on a routine

basis and sign off on those Care cards.

Keys to Accident Prevention:

1. Follow all safety procedures

2. Follow all instructions on the Permits

3. Conduct Hazard Assessment

4. Pre-Lift meeting with all participants

5. Question all uncertainties

6. Be aware of all surroundings and pause to assess the job for any changing conditions.

Page 1 of 2



of 25

Appendix E (continued)

CARE Card (Example)

Crane Checklist Crane Lift Requirements Rigging Requirements

Crane Type:

Capacity:

1) Crane Certified? ______________

2) Operator Certified to operate crane?

3) Weather Conditions?

4) Wind Speed?

5) Electrical Lines Present?

Clearance _______________ft

6) Crane Inspected Prior to Lift? ____

7) Outriggers out, ground conditions

reviewed for pipelines and soil

stability, mats needed and in place?

Other Hazards:

A1) Boom Length __________________ft

A2) Radius _______________________ft

A3) Gross Capacity _______________lbs

Note: Only use the Load Chart for the Equipment

Model being operated.

B1) A3 x 0.80 = 80% Chart ________lbs

B2) Estimated Total Load ___________lbs

B3) Actual Load __________________lbs

CAUTION: If B2 is greater than B1, make

adjustments prior to lift (move closer, use

a larger crane, etc.).

CAUTION: If B3 is greater than B1, Stop

and Contact your supervisor or Valero

HEO.

CAUTION: If B2 is greater than B1, stop

and contact your supervisor or Valero HEO.

Page 2 of 2

1) Have rigging (wire rope/nylon), shackles and hooks been inspected? ___________________

2) Have lifting lugs or lift points been inspected? ___________________

3) Are dimensions or lifting points critical, if so, why? ______________________________________________________

4) Has spreader bar design and capacity been verified?

5) Point of Attachments (POA)

inspected and documents reviewed ___________________

6) Has sling load capacity been

checked? 7) Has tail clearance been reviewed? 8) Is tagline in place? ___________

Comments:

______________________________ __________________________________________________________________________________________



of 25

Appendix F

Rigging and Signal Person Qualification Requirements

1.0 Rigging Training

1.1 Rigging training shall meet the level of work to be performed.

1.2 Basic rigging training may include but is not limited to the following:

Identify and describe the use of slings and common rigging hardware.

Describe basic inspection techniques and rejection criteria used for slings and hardware.

Describe basic hitch configurations and their proper connections.

Describe basic load-handling safety practices and use of taglines

Understand sling capacities and angles.

Select, inspect, use and maintain special rigging equipment, including: o Block and tackle o Chain hoists o Come-alongs o Jacks o Tuggers

Identify basic rigging and crane safety procedures and determine the center of gravity of a load.

Identify the pinch points of a crane and explain how to avoid them.

Identify site and environmental hazards associated with rigging (power lines, weather, etc…).

Identify the components of a lift plan.

1.3 Competency should be assessed through knowledge verification and performance verification.

1.4 Know and understand the relevant requirements of OSHA general industry and construction regulations and industry standards (ASME) as it pertains to cranes and rigging.

2.0 Signal Person Training

2.1 Signal Persons must be assessed by a qualified evaluator (internal or third party) who has demonstrated competency in accurately assessing whether individuals meet the Qualification Requirements in 1926.1428.

2.2 Qualification Requirements

Know and understand the type of hand signals used in ASME B30.5-2007 Standard Hand Signals for Controlling Crane Operations.

Be competent in the application of the type of signals used.

Have a basic understanding of equipment operation and limitations, including:

o Crane dynamics (swinging and stopping loads and boom deflection from hoisting loads) o Dangers of working around power lines (step and touch potential and clearances) o Understand the requirements to keep clear of the load fall zone



of 25

Know and understand the relevant requirements of 1926.1419 (Signals – general requirements), 1926.1420 (Signals – radio, telephone or other electronic transmission of signals; 1926.1421 (Signals – voice signals – additional requirements; 1926.1422 (Signals – hand signal chart); 1926.1428 (Signal person qualifications).

Competency shall be assessed through knowledge verification and performance verification.


Document Owner: VP Occupational and Process Safety ... Safety...Voltage (Nominal, kV, Alternating...

Documents

Transcript of Document Owner: VP Occupational and Process Safety ... Safety...Voltage (Nominal, kV, Alternating...