PowerLogistics Asia 2014 - Lifting & Hoisting - Best Practices – P V N Chandrasekaran, Weatherford...

Lifting & Hoisting Best Practices Chandra – QHSSE Manager for Weatherford Malaysia & Brunei

QHSSE | Lifting & Hoisting - Best Practices

Facility Orientation


About the presenter• Master of Science in Mechanical Engineering (NTU – Singapore)• Bachelor of Mechanical Engineering • Diploma in Mechanical Engineering

• 23 Years work experience – Onshore & Offshore, Oil & Gas, Petro-chemical, Power Station, FPSO & Marine industry

• Weatherford, Cameron & Sembawang Marine Offshore…etc• Expertise: QMS, ISO 9001, ISO 14001, OHSAS 18001, API Q2, Drilling, Completion,

Welding, FPSO, NDT, Materials, DS-1, NS-2 & Various international standards….

• TapRooT® Advanced Root Cause Analysis Team Leader • Quality & HSE Advisor • ISO 9001:2008 & OHSAS 18001 – 2007 Lead Auditor• Singapore Registered Workplace Safety Health Officer & Environmental Control officer


Safety Moment

Types of LIFT & Requirements

• Category of Lift • Required Control Measures• Required Competent

Personnel• Lift Plan Reviewed by

A. ROUTINE1. Risk Assessment (Generic)

2. Lift Plan i.e Crane log

3. Toolbox Talk

1. Crane operator

2. Deck Crew

3. Banksman level 1 & 2

1. Person In Charge (PIC)

B. NON-ROUTINE

- Simple 1. Risk Assessment (Generic)

2. Lift Plan (prepared by

competent rigger)

3. Permit To Work

4. Toolbox Talk

1. Maintenance Technician

2. Banksman level 1 & 21. Person In Charge (PIC)

- Complicated 1. Risk Assessment (Specific)

2. Lift Plan (Specific)

3. Permit To Work

4. Toolbox Talk

1. Lift Planner

2. Rigging Supervisor1. Technical Authority (TA)

- Complex 1. Formal pack with method

statement

2. HAZID / HAZOP

3. Drop objects study

4. Lift plan prepared & reviewed by

qualified engineer

5. Permit to Work

6. Toolbox talk

1. Lift Planner

2. Professional Engineer1. Technical Authority (TA)

• The gross load is not exceeding 25 tonnes, and not exceeding 75% of the manufacture’s capacity chart at the working radius

• Standard rigging arrangements

• Suitable lay down area available

• Load with require certified lifting points or be relatively easy to sling

• Equipment installed by a competent person

• Load has known and evaluated, shape and center of gravity

• Use of certified lifting point directly above the load

• Ample headroom

• Lifting in non sensitive, non difficult or unrestricted areas

• Single lifting appliances

• Unlikely to be affected by environmental conditions

• Experienced and competent equipment operator.

• Hoist suspended from a dedicated lifting structure such as pad eyes or runaway beams

• Lifts from one offshore vessel to another

Category of LiftRequired Control

MeasuresRequired Competent

PersonnelPlan Reviewed by

B. NON-ROUTINE

- Complicated 1. Risk Assessment (Specific)

2. Lift Plan (Specific)3. Permit To Work4. Toolbox Talk

1. Lift Planner2. Rigging Supervisor

1. Technical Authority (TA)

• The gross load is greater than 25 tonnes

• The gross load represents more than 75% of the manufacture’s capacity chart at working radius or

• The gross load is greater than 20 tonnes and is also greater than 80% of the manufacture’s capacity chart.

• Continuation of a lifting operation with different equipment (due to malfunction, inadequacy or unsuitability),

• Use of two or more items of Lifting Equipment including tailing pipe using winch and crane (tandem lifting)

• Within sensitive, difficult or unrestricted areas

• Load that requires to be rotated or cross hauled involving two or more sets of rigging

• Awkward shape, offset or high center of gravity, fragile, containing liquids

• No lifting attachment and difficult to sling

Category of Lift Required Control MeasuresRequired Competent

PersonnelPlan

Reviewed by

B. NON-ROUTINE -Complex

1. Formal pack with method statement2. HAZID / HAZOP3. Drop objects study4. Lift plan prepared & reviewed by qualified Eng.5. Permit to Work and Toolbox Talk

1. Lift Planner2. Professional

Engineer

1. Technical Authority (TA)

• The gross load is greater than 75 tonnes or

• The gross load represents more than 90% of the manufacture’s capacity chart at the working radius or

• The gross load is greater than 50 tons and is also greater than 80% of the manufactures capacity chart

• Continuation of a lifting operation with different personnel e.g. shift change over

• Lifting of personnel, including drill floor Man-Riding operations

• Over or in sensitive areas e.g. active or energized hydrocarbon-containing process equipment

• Transferring the load from one lifting appliance to another

• In environmental conditions likely to affect equipment performance

• Operator under training

• Load with unknown or difficult to estimate weight and/or center of gravity

• Load is special and/or expensive the loss of which would have a serious impact on production operations

• Non standard rigging arrangements

• Load lowered into or lifted from a confine space

• Sub-sea lifting; Lift involving floating cranes

• Extremely heavy loads

10

DEVELOP HANDS FREE CULTURE WITH 5 “HANDS-FREE” RULES

1 2 3

4

5

No Hands On Load

11

Hand on Handles Only

12

Permission to touch 20kgs

13

Hands Free Container Loading

14

Tag line attached on designated point.

No hands on load, Use Tag Lines


15

D-rings on Multiple-legged slings

accessible from ground level for

attachment to crane hook.


15

Hands Free Campaign Stickers on

baskets and containers

Load well secured inside tool

basket with nylon straps.

Safe Cargo Loading

17

Impact Resistant Gloves

18


Maintain a Hands Away philosophy

� Hand and finger injuries continue to be the most common incidents at Weatherford

� Almost everything we do involves our hands and fingers, our exposure is significant

� To reduce the risks, keep your hands off loads!

• Use tag lines or push/pull bars to control loads

� We are not permitted to touch a load while it is in motion or under tension

HOW TO SELECT CORRECT WIRE ROPE SLINGS

High Risk Most common non compliance!

Most of the contractor are using wire rope slings for lifting their equipment to transport

onshore and offshore premises, however it has been observed that the capacity of the

wire rope slings being used for the particular equipment, has no Enhancement factor to

compensate dynamic factors during lifts.

What is Enhancement factor?

The enhancement factor is higher degree selection of slings for containers, because

containers are subject to the most severe dynamic amplification due to dynamic

amplification that will be experienced in offshore lifting in adverse weather, sea states,

crane behavior and operator skill.

What is Right?

All lifting equipment and lifting gears used in the lifting process shall be rated at

30% or more above the maximum load to be lifted as per our Shell Lifting and Hoisting standard..

The minimum working load limit, of the lifting sets for offshore containers shall be

determined for the lifting set and each of its components according to

enhancement factor , and the rating of a container is multiplied by an

enhancement factor to give an enhanced requirement for the working load limit

of the sling as per the standard. If the equipments is designed and fabricated as

per the relevant standard of BS EN 12079-1-2006 or DNV-2.7.1

OR


Simple Guide of sling selection.

Slings can be selected in two different method, and the methods are as follows:

1. Trigonometric method

2. Uniform method

1. Trigonometric method:

The trigonometric method is provides for progressive reductions in the working load

limit as the angle between the sling legs increase.

It assumes the operative is trained in the assessment of angle and requires the display

of a chart showing the working load limits which apply at various angle.

It strongly recommended that this method should only be used for slings designed for

a single purpose only.


Single leg sling = 1 x WLL of single leg

Two leg Sling = 2 x WLL of single leg x Cos β

Three leg = 3 x WLL of single leg x Cos β

Four leg Sling = 4 x WLL of single leg X cos β

In other cases the WLL for a four leg sling will be the same as for a three leg sling.


Example: 1

Single wire rope capacity of 26 mm = 7.8 t (This could vary based on minimum Breaking load)

To obtained the capacity of two leg sling by using trigonometric method

capacity of two leg = 2 x WLL of single leg x Cos β

= 2 x 7.8 x cos β (Which is the angle between the legs)

= 2 x 7.8 x cos 30°

= 2 x 7.8 x 0.866 ( Cos 30°= 0.866)

Therefore the total capacity of the two leg slings will be = 2 x 7.8 x 0.866 =13.5 t

NOTE: Please note that this method should only be used for slings designed for a

single purpose only


Example: 2


To obtained the capacity of three leg slings by using Trigonometric method

Capacity of three leg = 3 x WLL of single leg x Cos β

= 3 x 7.8 x cos β (Which is the angle between the legs)

= 3 x 7.8 x cos 30°

= 3 x 7.8 x 0.866 ( Cos 30°= 0.866)

Therefore the total capacity of the three leg slings will be = 3 x 7.8 x 0.866 =20.26 t

NOTE: Please note that this method should only be used for slings designed for a

single purpose only


2. Uniform method

The uniform method is the simple option, having inherent safety advantages, permitting

only one working load limit to the angle to vertical legs maximum of 0-45°

Single leg sling = 1 x WLL of single leg

Example-1


To obtained the capacity of two leg slings by using Uniform Method

Capacity of two leg = WLL of single leg x 1.4 (Mode factor)

= 9.0 x 1.4 (Which is the angle to the vertical legs cos45°+ cos45°= 0.707 +0.707 =1.4)

= 9.0 x1.4 = 12.6 t

Therefore the total capacity of

the two leg slings will be = 9.0 x 1.4 =12.6 t


Example-2


To obtained the capacity of Three leg slings by using Uniform Method

Capacity of Three leg = WLL of single leg x 2.1 (Mode factor)

= 9.0 x 2.1 (Which is the angle to the vertical legs cos45°+ cos45°= 0.707 +0.707 +0.707=2.1)

= 9.0 x 2.1 = 18.9 t……say =19 t


the three leg slings will be = 9.0 x 2.1 =19.0 t


Example-3


To obtained the capacity of Four leg slings by using Uniform Method

Capacity of Four leg = WLL of single leg x 2.1 (Mode factor)

= 9.0 x 2.1 (Which is the angle to the vertical legs cos45°+ cos45°= 0.707 +0.707 +0.707=2.1)

= 9.0 x 2.1 = 18.9 t……say =19 t


the four leg slings will be = 9.0 x 2.1 =19.0 t

Note: 4th leg is only retardant sling, hence 3 & 4 legs remain same capacity

In other cases the WLL for a four leg sling will be the same as for a three leg sling.


Please refer the below chart as per BS EN 13414-1-2003, which is uniform method

of selection of the slings steel cored rope of classes 6x19, 6x36 and 8 x 36 and

having ferrule-secured eye terminations;


Please refer the below chart as per BS EN 12079-2-2006, and DNV 2.7.1,

which has enhancement factor for selection of the slings .


• http://www.mom.gov.sg/legislation/occupational-safety-

health/Pages/default.aspx

• Part I – Preliminary

• Part II – General Provisions

• Part III – Registration of Crane Operators

• Part IV – Appointment and Duties of Personnel

• Part V – Installation, Repair, Alteration, Testing and Dismantling of

Mobile Crane or Tower Crane

• Part VI - Miscellaneous

Workplace Safety and Health (operation of Cranes)

Regulations 2011

Staying focused Video


Lifting incidents don’t happen often, but when they do, they can be catastrophic!

Lifting is a High-Exposure Activity

If you see an unsafe act,

behavior, or unidentified

hazards…stop work!


THANK YOU

®

PowerLogistics Asia 2014 - Lifting & Hoisting - Best Practices – P V N Chandrasekaran, Weatherford...

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