Lifting Operations

BP Pakistan

Exploration & Production, Inc.

LIFTING OPERATIONSLIFTING OPERATIONS

Document No: PRO/SFTY/017

Document No.: Rev. No.: Issue Date:

PRO/SFTY/017 0 September 11, 2001

Sponsored by: Endorsed by: Approved by:

HSE

(Rafique A. Moghul)

Supply Chain Management

(Mohammad Fahim)

Davison Manager

(Mausuf Ahmad)

BP Pakistan Exploration & Production, Inc.

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DOCUMENT CONTROL

Revision Record

Revision No.

Revision Date

Section / Page Description & Reason for amendment

Document No.: PRO/SFTY/017 Issue Date: Sept. 11, 2001 Page 1 of 15


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TABLE OF CONTENTS

1.0 INTRODUCTION......................................................................................................................................3

2.0 PURPOSE...................................................................................................................................................3

3.0 SCOPE........................................................................................................................................................3

4.0 DEFINITIONS...........................................................................................................................................3

5.0 COMPONENTS OF SAFE LOAD LIFTING JOB................................................................................6

6.0 RESPONSIBILITIES................................................................................................................................7

6.1 LOCATION SUPERVISORS..............................................................................................................................76.2 RIGGING SUPERVISOR...................................................................................................................................76.3 CRANE SAFETY WATCH...............................................................................................................................96.4 LIFTING EQUIPMENT OPERATOR..................................................................................................................9

7.0 PREVENTIVE MAINTENANCE, INSPECTION, AND CERTIFICATION..................................10

8.0 RECORDS OF INSPECTIONS, TESTS AND CERTIFICATION....................................................12

9.0 LIFTING GEAR......................................................................................................................................12

10.0 INSPECTION / TESTING OF LIFTING GEAR.................................................................................13

11.0 MANPOWER CERTIFICATION.........................................................................................................14



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1.0 INTRODUCTION

Lifting equipment cannot create accidents by themselves. They are inanimate objects designed and operated to raise and lower loads efficiently and safely within the stated capacities. Accidents with lifting equipment can only be caused by man's action or inaction.

BP's Golden Rules of Safety state that lifts utilizing cranes, hoists, or other mechanical lifting devices will not commence unless:

An assessment of the lift has been completed and the lift method and equipment has been determined by a competent person(s).

Operators of powered lifting devices are trained and certified for that equipment.

Rigging of the load is carried out by a competent person(s).

Lifting devices and equipment have been certified for use within the last 12 months (at a minimum).

Load does not exceed dynamic and/or static capacities of the lifting equipment.

Any safety devices installed on lifting equipment are operational.

All lifting devices and equipment have been visually examined before each lift by a competent person(s).

2.0 PURPOSE

The purpose of this procedure is to ensure safe working conditions and practices during lifting operations carried out within Company work sites, either by Company or Contractor employees.

3.0 SCOPE

This document is to ensure that all mechanical lifting operations conducted across BP Pakistan's operated facilities and rigs, including those involving contractors and contractors’ equipment, are in compliance with applicable regulatory and Company requirements, whichever are the highest. Compliance with this document is mandatory. Deviations from this program will require an approved Management of Change.

4.0 DEFINITIONS

The following definitions shall assist in the understanding of this procedure:

Certified Rigging Personnel

Rigging Supervisor, Safety Watch, Crane Operators, and Signalman/Banksman who have undergone training and subsequent certification by a BP Pakistan-approved Third-Party Inspection Authority.



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Company Representative A person who, by virtue of appointment, has authority to represent BP Pakistan in all matters with the Contractor concerning performance of work, provision of services, or supply of goods.

Crane Safety Watch A Company employee or contractor who has undergone training and subsequent certification by a Company-approved Third-Party Inspection Authority and is responsible for safe load lifting operation of a crane. His presence is mandatory for all "Critical Lifts."

Critical Lift Any load-lifting job that is out of the ordinary or may approach the limitations of the lifting equipment or skill level of the operators. Critical lifts include, but not limited to, Heavy Lifts (80% of crane capacity), High-wind Exposure Lift, High Cargo Cost Lift, High Risk (Fire or Explosion) Lift, Fragile Cargo Lift, Hazardous Environment / Visibility Lift, and Danger Zone Lifts liable to cause partial or total shutdown of the plant.

Danger Zone of Lifting Equipment

The area around a lifting equipment that may be affected in case of lift failure. Arithmetically it is estimated as horizontal radius of lift plus the largest dimension of load that is to be lifting.

(Danger Zone = Radius of lift + Largest of the load dimensions)

Equipment Checklist List identifying attributes required to be checked and approved prior to equipment entry into Company work sites.

Facility Any location including Construction, Drilling, Maintenance, Productions, Warehouse, and Camps within Company area of operations where work is being carried out for and on behalf of the Company.

Facility-in-Charge / Location Supervisor

Company's senior-most supervisor who is present at the location and is responsible for carrying out operations within the facility area.

Fail-safe Load If consequences of a load-lifting job are judged to be acceptable in case of equipment / lifting gear failure.

Lifting Equipment Operator

A Company employee or contractor who has undergone training and subsequent certification by a Company-approved Third-Party Inspection Authority and is designated to operate crane, forklift, etc. The operator should have appropriate experience and training (classroom and hands-on), and has also met the requirements of a qualified rigger.



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Lifting Gear Equipment and equipment parts used in fastening or securing loads for mechanical lifting such as a chain, sling, rope sling, ring, link, hook, plate clamp, shackle, swivel, eyebolt, or similar gear.

Load Test Method of verifying the capacity of a lifting equipment by lifting a "dummy" load of known weight at a measured radius, and then performing different maneuvers, i.e., hoisting, lowering, slewing (swinging) at 180 degrees, and finally lowering the load from about five feet height at full speed and suddenly stopping when load is one foot above ground. Dummy load should be 10-25% above the equipment's rated capacity or according to manufacturer's recommendations. The test is done in the presence of a Company representative.

Rigging Supervisor A Company employee or Contractor who has undergone training by a Company-approved Third-Party Inspection Authority and has a minimum of five years experience in supervising lifting operations. His presence is mandatory for all Critical Lifts.

Safe Working Load (SWL) The relevant safe working load required to be specified in records of test and examinations, and to be marked on the lifting equipment and the lifting gear.

Signalman / Banksman A person who has undergone training and subsequent certification by a Company-approved Third-Party Inspection Authority for signaling the Lifting Equipment Operator during a lifting job.

Tandem / Multiple Lift Lifting operations involving use of more than one crane. Cranes used should have equal lifting capacities.

Task Risk Assessment (TRA)

Tool used for listing distinct activities within a job identifying various associated risks, categorizing these risks on severity, and chalking-up a safety plan to remove/control such risks. Technique is mainly used for non-routine / critical lift jobs.

Third-Party Inspection Authority

An internationally recognized crane and lifting equipment inspection agency approved by BP Pakistan.

Work Permit A document issued by a Permit Issuing Authority allowing the performance of specific tasks in a specified location for a specified duration, identifying associated hazards and control measures required.



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5.0 COMPONENTS OF SAFE LOAD LIFTING JOB

Following activities shall be ensured to achieve safe load lifting jobs.

5.1 Every employee is authorized to stop any unsafe rigging operation.

5.2 It will be ensured that lifting equipment, hoists, and all lifting gear are fit for use and their certification by a BP Pakistan approved Third-Party Inspection Authority valid.

5.3 Inspection of Company and contractor cranes and associated rigging equipment will be carried out in accordance with the Standing Instructions document SI/001.

5.4 It will be ensured that Task Risk Assessment (TRA) is reviewed and approved prior to commencing non-routine/critical-lift jobs. If a lift is classified as critical, then additional precautions should be taken (load tests, consultations, additional safety reviews, dry runs, etc.) to increase the assurance that the lift will be completed in the safest possible manner.

5.5 A current list of certified crane operators and riggers will be maintained on all BP Pakistan operated facilities and rigs on the database by Contract Sponsor/Purchasing Department.

5.6 It will be ensured that personnel involved in the rigging operation (BP Pakistan/Contractor Supervisors, Operators, Signalman, and Safety Watchman) are all certified and that their on-the-job performance is observed and examined.

5.7 Crane load limits are adhered to at all times. The crane operator will know the weight of the load and assure that it is within acceptable limits on the load chart before lifting.

5.8 Crane load-radius charts for static and dynamic lifting will be located in plain sight of the operator and used for each lift.

5.9 Riggers and signalmen will be competent in the use of appropriate hand signals.

5.10 It will be ensured that no lifting job commences without Rigging Work Permit being issued first, as per the Permit To Work procedure.

5.11 Personnel will avoid being under any part of the crane boom or load.

5.12 A Preventive Maintenance (PM) program is required for all cranes (see Section 7.0).

5.13 Lifting equipment that satisfies the SI/001 checklists shall be deployed within BP Pakistan work areas/facilities. This equipment in turn shall be operated/handled by authorized personnel under BP Pakistan certified supervisors and after obtaining appropriate work permits.

5.14 It will be ensured that ground conditions are suitable enough to bear the total weight (the load being lifted plus the weight of lifting equipment). Therefore, ground condition must be



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checked/tested and extra sleepers/plates placed underneath outrigger plates for critical lifts. Ensure that wooden sleepers or steel plates are always kept with crane for this purpose.



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5.15 A well-engineered written lifting-plan, where one person is in-charge and every crewmember has been briefed about his tasks, exists. A lifting plan should elaborate step by step activities in order of their occurrence along with calculations and should contain following as minimum information:

5.15.1. Weight of the load to be lifted with its dimensions and probable centre of gravity.

5.15.2. Weight of lifting slings, hooks, spreader bars, pulleys, etc.

5.15.3. Details of duty chart of lifting equipment and an attested copy of the chart in case it is not available in operator’s cabin.

5.15.4. Dimensions of crane/lifting equipment along with sketches showing slinging points on load, various positions and angles of boom, lifting capacities at those radii and clearances of slings / hooks /pulleys.

5.15.5. It is recommended that all the dimensions be drawn to scale including equipment, load sizes, and site clearances. Side and plane views are a must for tandem lift (when two cranes are used simultaneously to lift a load) along with tailing arrangement.

5.15.6. Safety aspects including safe removal of slings are mentioned in it.

6.0 RESPONSIBILITIES

Following personnel are responsible for ensuring compliance with this procedure, and with applicable regulatory requirements relating to mechanical lifting operations:

6.1 Location Supervisors

Location Supervisors shall include Facility In-charge, Project Managers, Construction Managers, Construction Superintendent, Warehouse/Purchasing Manager, Production Superintendent, Field Operation Engineer, and Rig Move Coordinator. They shall ensure that:

6.1.1 A Rigging Supervisor is appointed to control the inventory of lifting equipment and arrange its periodic examination/certification in accordance with applicable regulations and standards.

6.1.2 All supervisors involved in lifting operations understand the requirements of the procedure.

6.1.3 A system of review and control is established to ensure that standards are appropriate to the requirements of the operation.



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6.2 Rigging Supervisor

At all stages during the progress of a lifting operation, from planning through to completion, the Rigging Supervisor shall ensure that all necessary precautions are in place to carry out the job in the safest possible manner. His responsibilities include:



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Lifting Equipment

6.2.1 Maintaining a current inventory of lifting equipment and gear including their conditions and serviceability.

6.2.2 Ensuring lifting equipment and gear undergo periodic inspection and certification, and are in good working condition. Load testing shall be performed where required.

Rigging Personnel

6.2.3 Ensuring that all Rigging personnel are competent and properly trained, and Certified Rigging Personnel are in possession of valid certificates.

Safe Lifting Operation

6.2.4 Determining, along with the Job-Site Representative, if a lift is critical or non-critical.

6.2.5 Ensuring that a Task Risk Assessment (TRA) is carried out, if required.

6.2.6 Making sure that rigging plan for a critical lift is available in writing at Site.

6.2.7 Obtaining the necessary Work Permit / Vehicle Entry Permit.

6.2.8 Ensuring that conditions are suitable for the operation (i.e., ground conditions, weather conditions, and wind direction/speed).

6.2.9 Making sure that safety briefings and assigning of tasks/duties have been done prior to start of a critical lift.

6.2.10 Ensuring that the load does not exceed the dynamic and/or static capacities of the lifting equipment.

6.2.11 Ensuring that the load is known and its center of gravity is the lifting point, or the lifting slings straddle this point.

6.2.12 Ensuring that load is free from any engagement or unknown force before lifting.

6.2.13 Ensuring that load is kept as close to the ground as possible.

6.2.14 Ensuring that no one is on the load or underneath the load.

6.2.15 Making sure that the danger zone is free from standby observers.



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6.3 Crane Safety Watch

The Crane Safety Watch shall:

6.3.1 Visualize various positions of the load before actual lift.

6.3.2 Observe that the crane is leveled on a firm ground and it remains leveled during the entire lift.

6.3.3 Examine that two hold off wires/tag lines are tied up with the load and controlled by riggers.

6.3.4 Monitor that truck-mounted crane lifts over the back, never over the cab.

6.3.5 Examine that slings are not used at wide angles. Preferable angle of slings with respect to load is 90 degrees. It may not be always possible to sling a load at 90 degrees, so the angle may be less than 90 degrees, but less than 60 degrees should be avoided.

6.3.6 Examine that all links, rings, shackles ride the hooks freely.

6.3.7 The load on the hook shall be applied only at the bottom of the circular part of the hook, whatever type of hook is in use.

6.3.8 Ensure that when two eyes from spreader slings are required to be brought back on to one hook, they shall be first brought into a shackle that in turn shall be hung freely from the hook.

6.3.9 Monitor that riggers are properly dressed - loose clothes and leather gloves are discouraged. Safety shoes with rubber sole are preferred.

6.3.10 Examine that outriggers are set to the maximum possible width.

6.3.11 Examine that outriggers remain under watch throughout the job execution.

6.3.12 Slings are not run around sharp corners or shortened using knots or attached to a fitting that is smaller than sling rope in diameter.

6.4 Lifting Equipment Operator

Lifting Equipment Operators include certified operators of Cranes, Gang Truck, and Forklift. He is responsible for his lifting equipment and shall:

6.4.1 Check the condition of the lifting equipment before starting work.

6.4.2 Report to his supervisor any obvious defects or required repairs.

6.4.3 Never elevate a load with the lifting equipment on an incline, until machine is leveled.



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6.4.4 Carry loads as close to the ground as possible.

6.4.5 Ensure that when reversing the vehicle, at least one person is signaling from the rear (at least two persons when inside the plant).

6.4.6 Ensure that he does not rely on horn beep safety.

6.4.7 Ensure that starts and stops are done gradually and slowly.

6.4.8 Maintain a safe distance from other vehicles when travelling the lifting equipment.

6.4.9 Never overtake other vehicles while load is lifted.

6.4.10 Avoid stunt driving and horseplay while operating the lifting equipment.

6.4.11 Slow the vehicle down on wet and slippery surfaces.

6.4.12 Go slow and sound the horn at corners.

6.4.13 Avoid running over loose objects.

6.4.14 Always watch load and mast overhead clearance.

6.4.15 Keep hand and feet inside the lifting equipment.

6.4.16 Not allow the lifting equipment parts to strike other objects.

6.4.17 Observe ground condition and ground load limits.

6.4.18 Use an assistant when going up or down a ramp.

6.4.19 Not carry passengers on the lifting equipment.

6.4.20 Shut off his lifting equipment, lower the boom, and tie hook with machine body before leaving it unattended.

6.4.21 Not smoke on the job.

6.4.22 Check the condition of his lifting equipment after a day's work.

7.0 PREVENTIVE MAINTENANCE, INSPECTION, AND CERTIFICATION

A Preventive Maintenance (PM) Program shall be applied to all Company-owned lifting equipment in accordance with the manufacturer's specifications and records kept in the Maintenance tracking system. Maintenance program shall include not only mechanical components, but also all alarm/safety devices and lifting accessories. In addition to the regular maintenance, all lifting equipment shall be inspected and certified every year by a Company-approved Third-Party Inspection Authority. The examiner shall issue certificates to equipment clearing inspection.



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All lifting equipment should also have the required local government certificates, where applicable.

Rental equipment that stays with the Company will also follow a Preventive Maintenance Program covering all mechanical and safety aspects. A PM program checklist, which is based on recommendations from equipment's manufacturer, is to be pre-approved by Company representative. This checklist is to be maintained by the Contractor and provided to the Company representative upon request prior to lifting operation. In addition to the regular maintenance, all contractor-owned lifting equipment shall be inspected and certified every year by a Company-approved Third-Party Inspection Authority. The examiner shall issue certificates to equipment clearing inspection.

Once the lifting equipment and the associated lifting gear have been certified, the following shall apply:

7.1 Lifting equipment shall not be allowed to be used unless current records of tests and examinations are made available to Company representative. To be current, records must show that the lifting equipment has been tested and thoroughly examined satisfactorily by a Company-approved Third-Party Inspection Authority within the previous 12 months (or since the last substantial alteration or repair that could affect its stability).

Any lifting equipment that has been altered or repaired will have to be re-certified by the Company-approved Third-Party Inspection Authority. To do this, Contractor shall provide a document stating alterations/repairs carried out. These alterations/repairs can be due to contractor's own maintenance program or can also be in response to Company inspections and subsequent remedial actions.

7.2 All wire ropes, chains, and slings shall be tested and certified by a Company-approved Third-Party Inspection Authority before first use. Lifting Gear shall not be used unless there are current records of tests and examinations. To be current, records must show that the Lifting Gear has been tested and thoroughly examined satisfactorily by a Company-approved Third-Party Inspection Authority within the previous 12 months (or since the last substantial alteration or repair that could affect its stability). Any Lifting Gear that has been altered or repaired will have to be re-certified by the Company-approved Third-Party Inspection Authority. To do this, Contractor shall provide a document stating alterations/repairs carried out. These alterations/repairs can be due to contractor's own maintenance program or can also be in response to Company inspections and subsequent remedial actions.

Additionally, all Lifting Gear shall be thoroughly examined every six months and records maintained by the contractor. The Company reserves the right to request proof of inspections at any stage of the work.

7.3 Any lifting equipment, accessory, sling, shackle, which has been tested and certified by a Company-approved Third-party Inspection Authority shall only be visually inspected (per Rigging Procedures in rigging books) before load lifting.



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7.4 All hoists shall be tested and thoroughly examined before first use and after substantial alteration or repair. These shall be thoroughly examined every six months.



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7.5 All critical load-lifting jobs shall require physical load testing of the Lifting Equipment and the Lifting Gear within 250-meter radius of the actual load-lifting spot.

7.6 Prior to its entry in a facility or rig site, it is mandatory that Lifting Equipment qualifies SI/001 checklist.

7.7 It shall be verified that a Load Moment Indicator (LMI) or Load Moment Limiter (LML) is installed and functional.

7.8 Outriggers will be checked for their functionality.

7.9 Adequate guarding of moving parts, including within the operator's cabin should be verified.

7.10 Safe access for the crane to the work site should be ensured.

8.0 RECORDS OF INSPECTIONS, TESTS AND CERTIFICATION

The Contractor will provide records of all inspections, tests, and certifications performed in Section 7.0 to the Company representative prior to lifting operation. Contract Sponsor/Purchasing Department (CS/PD) shall maintain these records so that a central database is available for immediate reference. CS/PD will then ensure that this information is disseminated and readily available at all Company work sites.

9.0 LIFTING GEAR

The following shall be ensured for all Lifting Gear:

9.1 All new Lifting Gear shall be certified by the manufacturer or the supplier and shall be supplied with a certificate specifying identification number and safe workload.

9.2 Lifting Gear produced, modified, or repaired locally shall be designed and manufactured according toe applicable industry standards (ISO, ANSI, BSI, etc.) and shall be inspected, load-tested, and certified by a Company-approved Third-Party Inspection Authority prior to use, and the inspection documented.

9.3 The Safe Working Load (SWL) will be clearly indicated on all Lifting Gear. SWL can be marked on the equipment, or on a tag fastened to the equipment.

9.4 Welding on any type of lifting equipment is not permitted.

9.5 Wire rope purchased for use in a crane winch shall be the same type and capacity as the wire rope supplied by the crane manufacturer. The wire rope shall be purchased with certification from the supplier. All certification documents shall be kept on file until the wire ropes are discarded.



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9.6 Lift slings shall be purchased with the correct sockets. Never make lift slings from existing wire rope in the field.

9.7 Plastic coating shall not be permitted on wire rope slings. Lubricant is the only coating permitted on slings.

9.8 Only steel alloy type of chain is permitted in hoisting. The chain shall be identified by a letter code on the chain links.

9.9 Pins, shackles, and clevises shall be of approved types and shall not be replaced with bolts.

9.10 All lifting accessories shall have a SWL rating that is more than the rating for the sling or chain.

10.0 INSPECTION / TESTING OF LIFTING GEAR

All winch cables and lift slings shall be inspected for the following before each use:

10.1 Six broken wires in one lay of length, or three broken wires in one strand in one lay of the length.

10.2 Two or more broken wires at the socket end of the cable.

10.3 Bends, twists or other damage affecting the shape of the rope or causing the twist of the rope to become loose.

10.4 Indications of heat damage.

10.5 A large area of corrosion.

10.6 End attachments that are worn, cracked, or broken.

10.7 Cables and slings have a coating of lubricant to prevent corrosion and reduce friction. If the lubrication that was applied at the factory has been removed, the cable/sling shall be cleaned and a new coating applied during inspection.

10.8 Slings that become wet with salt water shall be washed with fresh water and dried prior to lubrication.

10.9 Chains shall be inspected for bends, damage, cracks, and marks that can weaken the links.

10.10 Rings and hooks shall be inspected for a change in shape, cracks in the welds, and deep cuts.



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10.11 All hooks, shackles, clevises shall be inspected for:

a) Cracks, twists and wear on the part that lifts the load.

b) Indications that the hook has opened more than normal or twisted more than 10 degrees from the plane of the unbent hook.

c) Correct operation of the safety latch.

d) Wear in the top part of clevises and shackles.

e) Indications that the jaws of shackle or clevis are open more than normal.

f) Pins are of the correct type and are not worn-out or damaged.

If any defects found during the inspection are not repairable, the equipment shall be destroyed and discarded. Equipment with repairable defects shall be red-tagged and stored separately until repaired.

11.0 MANPOWER CERTIFICATION

11.1 Company-approved Third-Party Inspection Authority shall certify Rigging Supervisors, Crane/Forklift Operators, Crane Safety Watchman, Signaller/Banksman, and any other personnel deemed requiring certification in lifting operations.

11.2 Personnel without certification from Inspection Authority, whether Company employee or contractor, shall not be permitted to perform critical activities during lifting operations.

11.3 Contractors shall provide the Company with a list of personnel with proper certification. This list will be maintained at all Company work sites. Names of contractor operators will be checked against this list whenever performing lifting operations.

11.4 Certified contracted personnel may be interviewed/tested by Company representative during the current or subsequent assignment to Company work site. The following are guidelines for the interview/test:

a) Operator's relevant experience for a particular job to be undertaken.

b) Previous safety performance and/or incidents.

c) Medical fitness for work.

d) Any evidence of drug or alcohol intoxication.



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e) Comprehension and understanding of his task, function of the lifting equipment (for operators), and knowledge of hand signals.

f) Observation of actual job performance.

11.5 Any personnel responsible for an accident involving lifting operations shall have his certification cancelled and will have to go through a re-certification process. The Company reserves the right to refuse deploying the involved personnel for future operations.

11.6 During long lifting operations such as rig moves, the operator shall be allowed two (2) 15-minute breaks and one (1) 30-minute meal break during the shift. Excessive operator fatigue should be avoided


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