RELIANCE GAS PIPELINES LIMITED
Dahej Nagothane Ethane pipeline Project
LIFTING & RIGGING PROCEDURES
LIFTING & RIGGING PROCEDURES
RECORD OF REVISIONS
Date Revision Details Revision
Number
20.11.2015 Issued for Implementation 0
Contents
1. Purpose...............................................................................................................4
2. Scope...................................................................................................................4
3. Application.......................................................................................................... 4
4. Abbreviations...................................................................................................... 5
5. Definitions...........................................................................................................5
6. Responsibilities....................................................................................................7
7. General Requirements.........................................................................................8
8. Risks Associated with Mobile Crane Operations...................................................9
10. Lifting of Personnel with Basket or Similar Device............................................... 17
11. Training/Validation/ Licensing/Evaluation........................................................... 24
12. Rigging Points of Contact.....................................................................................26
13. Procurement and Hire.........................................................................................27
14. Critical Lifts Permits, Risk Assessment and Lift Plan............................................. 27
15. Assembly / Disassembly, Inspections, Tests, and Maintenance of Cranes............29
16. Maintenance, Repairs, and Recertification.......................................................... 39
17. Modifications...................................................................................................... 40
18. Riggers / Rigging..................................................................................................40
19. General Safety Guidelines for Chain Pulley Blocks............................................... 41
20. Safety Guidelines for Winch................................................................................ 42
21. Air Tugger Operations / Pneumatic Hoist............................................................ 43
22. Gin Wheels..........................................................................................................44
24. Guidelines for use of Tower Crane...................................................................... 46
25. Steel Erection......................................................................................................53
26. Variances............................................................................................................ 53
27. Resources........................................................................................................... 53
28. References.......................................................................................................... 54
29. Attachments........................................................................................................55
1. Purpose
This procedure defines the requirements for the safe operation of rigging
activities.
2. Scope
This procedure includes the following major sections:
• Responsibilities
• General Requirements
• Training and Licensing /Validation
• Rigging Points of Contact
• Procurement and Hire
• Critical Lifts Permits, Risk Assessment and Lift Plan
• Assembly / Disassembly, Inspections, Tests, and Maintenance of Cranes
• Modifications of Cranes
• Chain Pulley Blocks
• Winch
• Air Tugger / Pneumatic Hoist
• Gin Wheels
• Hydra Cranes
• Steel Erection
3. Application
1. This procedure applies to work activities and employees under the control
of the DNEPL Program Project Management Team (PMT) and its
contractors / subcontractor
Abbreviations
PMT: Project Management Team
HSE: Health, Safety, and Environmental
ASME: American Society of Mechanical Engineers
WLL: Working Load Limit
SDP: Safe Driving Permit
SWL: Safe Working Load
JSA: Job Safety Analysis
4. Responsibilities
5.1 Contractors
• Nominate a rigging coordinator/engineer in‐ charge.
• Develop a lifting schedule, plan, and permits for all complex lift.
• Execute all lifts in accordance with this procedure.
5.2 Engineer in‐ charge
5.3 Engineer in‐ charge oversees the preparation and safe execution of all rigging
operations.
5.4 Prepare rigging plans for complex lift
5.5 Prepare critical lift permits, Risk Assessment checklist, Permit to Work (refer
10080‐1‐HSEF‐ DWP ‐CN‐016 Permit to Work) regarding cranes and rigging and
any required rigging designs.
5.6 Ensure that JSA and STA are prepared and communicated to all involved
employees.
5.7 Ensure that all lifts are executed in accordance with this procedure and
guidelines, instructions by J3 Program Area / Construction Manager.
5.8 Evaluate the qualifications/skill of field riggers and operators and determine that
they are qualified to perform the work they are assigned.
5. Site Field Engineer/Supervisor
5.9 All lifts require one experienced field engineer/supervisor.
5.10 Assist the operator in moving and setting up the crane.
5.11 Verify with the operator that the crane is set up correctly and is at the
correct operating radius.
5.12 Verify that the crane is not working above capacity/ criteria given in lift
category chart. (Refer to the Categories of Lifts section of this procedure).
6.2. J3 Program P&M
• Provide guidance and instructions to contractor rigging
coordinator/engineer in‐ charge.
• Develop and review inspection checklist and operating procedures.
• Establish crane procurement and hire specifications.
• Conduct initial operational test of crane and pre‐mobilization
requirements.
• Ensure periodic inspections and maintenance of crane.
• Validation of operator and signal person and maintain records.
• Approve any crane modification in line with in ‐country legal
requirements and manufacturers recommendations.
• Maintain records of testing, maintenance, repairs, and modification.
7. General Requirements
This procedure must be implemented and enforced by Area/Construction, P&M
and contractor management, their staff, the site HSE representative. The
requirements in this procedure have been structured to bring together and
combine the resources of DNEPL Program PMT and its contractors to achieve
ZERO crane and rigging incidents during the project.
7.1. Pre lift Meeting
A meeting attended by the crane operator, signal person, person (s) to be lifted,
and the supervisor responsible for the task to be performed will be held to
understand and ensure JSA, lift permit and STA requirements(refer Form 10080‐
1‐ HSEF‐FMT‐CN‐071 Pre‐Task Planning Signoff ) .
General requirement’s includes;
• To carry out material handling activity under close supervision.
• Use only tested and validated lifting tools and tackles for lift. Use of the
same within their SWL.
• Look for any visual damage of lifting gears such as wear and tear, kinks,
twisting, cuts, damage of threads, etc. and replace with good one.
• Protect sling from sharp edges by proper packing while wrapping slings
around load (structural member/pipe).
• Maintain sling angle between load and sling as per rigging scheme.
• Loading shall be done in such a way that center of gravity of load shall be in
line with lifting rope. Use more than 2 slings to balance load of irregular
shape (pipe loop etc.)
• Barricade entire area of lift operation. Don’t allow unauthorized person
inside barricaded area and under suspended load. Only the trained and
authorized person engaged in the job can work under the suspended load.
E.g. Persons engaged in slinging / de slinging, Persons involved in erection
job.
• Each time a crane is moved into service, or to a new location, the supervisor
must conduct an inspection of the area in which the crane will be operating.
• Safe means of access i.e. ladder with three point contact should be provided
to every part of a crane. If working above 1.8 meters (6 feet) fall protection
must be provided.
The dimensions of steel plates and bog mats should be determined by a
competent person, based on the type of mobile crane.
Equipped with wind gauges, hand held wind gauges may be used of providing
reliable method of wind measurement. Reference shall also consider authentic
meteorological site stations
To ensure the stability of a mobile crane in windy conditions, the following
factors should be addressed by the engineer in charge in consultation with J3
Program Construction / Area Manager:
• In many situations, even 36km/hour speed may be excessive, particularly
where the load and boom have large surface areas.
• Where the crane is lifting close to its rated capacity, the wind will have a
greater effect on the crane stability and the potential application of a side
load on the crane’s boom.
• Where the lift is a non‐standard lift, with a suspended load or large surface
area to be undertaken in windy conditions, a competent person should
provide written advice on safe lifting conditions.
• Winds in Jamnagar are high during afternoon and evening and during April
to October. All critical lifts should be planned in early morning to avoid
increase in wind velocity and to have less interference of workers at lifting
site. Also, area being prone to cyclones, check should be made for any
warning by meteorological department.
9.10. Emergency Procedures
During any emergency like failure of structure, bad weather, any incident, fire,
toxic gas or flammable gas release, mobile crane operator shall switch off the
crane, leave the ignition key in position and shall move to assembly area to take
further instructions.
9.11. Signal Person/ Banks man
Signal persons must be trained and tested on the signals to be used; this
includes voice and telecommunications signals as well as hand signals.
Signal persons must wear Orange Hi Visibility vests to improve recognition by
operator during any movement of a crane lift or travel
Only one person will assume signal duties and no other person will signal the
operator during the lift.
Exceptions:
• A person giving an emergency stop signal
• When 2 signal persons are needed for lifts
Signal persons will be trained in accordance with Attachment 05.
The signal person must have validation from the P&M department evaluator
who assesses the individual and determines that the individual meets the skill
requirements.
Contractor and PMT Engineer in charge/field engineer/supervisor shall ensure
that under no condition, such signal person shall operate crane.
Use of mobile phones/entertainment headphones during crane operation by
crane operator and signal person is stricly prohibited and will leads to
discipilinary action.
9.13. Working in Darkness
Night hours work should be planned by considering work hours , illumination,
rain and other environmental conditions. No work shall be carried out with
mobile crane in darkness if the area does not have proper illumination.
Contractor engineer incharge will not depend on the crane lights and it will be
his responsibility to arrange proper illumination of the area well in advance. Care
should be taken to avoid direct focusing of light on operator’s cabin.
Note: Avoid heavy lift operation in night hours. However in case any night heavy
lift is required, a hazard assessment must consider detailed planning, work hour,
time schedule, illumination, rain or environmental conditions and
communication limitations.
9.14. Rotating the Loads
When rotating the load, taglines or guidelines to control the arc and swing shall
be used. Lifting loads over workers shall not be permitted. Lifting load over the
cab of the crane, mechanical equipment etc should be avoided.
9.15. Statutory Requirements
• Cranes must meet applicable in country regulations and standards.
• Lifting equipment / rigging must meet applicable in country regulations and
standards.
9.16. Energized Power Lines
Any activity involving a crane (including assembly and disassembly) where there
is a potential for any part to come with 10.0 meters (33 feet) of an energized
power line requires special controls to be developed and implemented, refer to
10080‐1‐ HSEF‐ DWP‐CN‐054, Working Near Overhead Power Lines.
10. Lifting of Personnel with Basket or Similar Device
The use of a crane or derrick to hoist employees on a Man basket is prohibited,
except when the erection, use, and dismantling of conventional means of
reaching the worksite, such as a personnel hoist, ladder, stairway, aerial lift,
elevating work platform or scaffold, would be more hazardous, or is not possible
because of structural design or worksite conditions. Use of a Man basket shall be
approved by Area/Site Manager.
• Use of crane for man basket is the last option, at that point of time use of
specific crane to be planned to deploy in consultation with P&M.
Select the crane which has safety interlock redundancy out various
models of cranes described in chart.
Crane having lattice boom must be used. (which have safety features
against creeping / locking)
Crane with telescopic boom should not be used, because derrick
cylinder locking arrangement normally not available.
• Before work involving a man basket, Form Suspended Man Basket/ Platform
Checklist and Authorization/Permit (10080‐1‐HSEF‐CHK‐CN‐033) will be
completed by the supervisor and the required approvals obtained.
10.1. Operational Criteria
• Hoisting of the Man Basket shall be performed in a slow, controlled,
cautious manner with no sudden movements of the crane or derrick, or the
platform. Lifting and lowering speeds must not exceed 100 feet (30.5
meters) per minute.
• Load lines shall be capable of supporting, without failure, at least seven times
the maximum intended load, except that where rotation resistant rope is used,
the lines shall be capable of supporting without failure, at least 10 times the
maximum intended load. The required design factor is achieved by taking the
current safety factor of 3.5 and applying the 50 per cent of the crane capacity
(Interpretation :‐ 50% of the crane capacity available for the given configuration
and parameters should be considered for man basket lift)
• Outrigger pads must be used when lifting a suspended workbasket.
• The load line hoist drum must have controlled (power) load lowering
capability; free fall is prohibited and must be positively isolated.
• Load and boom hoist drum brakes, swing brakes, and locking devices such
as pawls or dogs shall be engaged when the occupied Man Basket is in a
stationary working position.
• The crane shall be uniformly leveled within one percent of level grade (one
% difference in level, reduces capacity around 10% on crane) and located on
firm footing. Cranes equipped with outriggers shall have them all fully
deployed following manufacturer's specifications, in so far as applicable,
when hoisting employees.
• The total weight of the loaded Man Basket and related rigging shall not
exceed 50 percent of the rated capacity for the radius and configuration of
the crane or derrick.
• The use of machines having live booms (booms in which lowering is
controlled by a brake without aid from other devices which slow the
lowering speeds) is prohibited.
• In this category of crane CLL (Controlled Load Lowering) arrangement is not
fully activated hence should not be allow for man basket.
• Crawler crane without CLL like (TFC‐280) model crane must not be used for
man lift.
Note: A safety wire rope sling will be affixed from the uppermost part of the
basket structure to a point above the ball or the dead‐end load line of the load
block.
10.2. Instruments and Components
• Cranes and derricks with variable angle booms shall be equipped with a
boom angle indicator analog / digital (Now a days digital indicators are
available in modern cranes) readily visible to the operator.
• Cranes with telescoping booms shall be equipped with a device to indicate
clearly to the operator, at all times, the boom's extended length, or an
accurate determination of the load radius to be used during the lift shall be
made prior to hoisting personnel.
• A positive acting device shall be used which prevents contact between the
load block or overhaul ball and the boom tip (anti‐two‐ blocking device), or a
system shall be used which deactivates the hoisting action before damage
occurs in the event of a two blocking situation (two block damage
prevention feature).
• The load line hoist drum shall have a system or device on the power train,
other than the load hoist brake, which regulates i.e. CLL the lowering rate of
speed of the hoist mechanism (CLL=controlled load lowering.) Free fall is
prohibited.
10.3. Design Criteria
• The Man Basket and suspension system shall be designed by a qualified
engineer or a qualified person competent in structural design.
• The suspension system shall be designed to minimize tipping of the Basket
due to movement of employees occupying the Basket.
• The Man Basket itself, except the guardrail system and personal fall arrest
system anchorages, shall be capable of supporting, without failure, its own
weight and at least five times the maximum intended load.
10.4. Man Basket Specifications
• Each Man Basket shall be equipped with a guardrail system and, shall be
enclosed at least from the toe board to mid‐rail with either solid construction or
expanded metal having openings no greater than \1/2\ inch (1.27 cm).
• A grab rail shall be installed inside the entire perimeter of the Man Basket.
• Access gates, if installed, shall not swing outward during hoisting.
• Access gates, including sliding or folding gates, shall be equipped with a
restraining device to prevent accidental opening.
• Headroom shall be provided which allows employees to stand upright in the
Man Basket.
• In addition to the use of helmet, employees shall be protected by overhead
protection on the Man Basket when employees are exposed to falling objects.
• All rough edges exposed to contact by employees shall be surfaced or
smoothed in order to prevent injury to employees from punctures or
lacerations.
• All welding of the Man Basket and its components shall be performed by a
qualified welder familiar with the weld grades, types and material specified
in the platform design.
• The Man Basket shall be conspicuously posted with a plate or other
permanent marking which indicates the weight of the Man Basket and its
rated load capacity or maximum intended load.
10.5. Man Basket Loading
• The Man Basket shall not be loaded in excess of its rated load capacity.
When a Man Basket does not have a rated load capacity then the Man
Basket shall not be used.
• The number of employees occupying the Man Basket shall not exceed the
number required for the work being performed.
• Man Basket shall be used only for employees and contract employees their
tools, and the materials necessary to do their work, and shall not be used to
hoist only materials or tools when not hoisting personnel.
• Materials and tools for use during a personnel lift shall be secured to
prevent displacement.
10.6. Man Basket Rigging
• When a wire rope bridle is used to connect the Man Basket to the load line,
each bridle leg shall be connected to a master link or shackle in such a
manner to ensure that the load is evenly divided among the bridle legs.
• Hooks on overhaul ball assemblies, lower load blocks, or other attachment
assemblies shall be of a type that can be closed and locked, eliminating the
hook throat opening. Alternatively, an alloy anchor type shackle with a bolt,
nut and retaining pin may be used.
• Wire rope, shackles, rings, master links, and other rigging hardware must be
capable of supporting, without failure, at least five times the maximum
intended load applied or transmitted to that component. Where rotation
resistant rope is used, the slings shall be capable of supporting without
failure at least ten times the maximum intended load.
• All eyes in wire rope slings shall be fabricated with thimbles.
• Bridles and associated rigging for attaching the Man Basket to the hoist line
shall be used only for the Man Basket and the necessary employees, their
tools and the materials necessary to do their work, and shall not be used for
any other purpose when not hoisting personnel.
10.7. Trial Lifts, Inspection, and Proof Testing
• A trial lift with the unoccupied personnel platform loaded at least to the
anticipated lift weight shall be made from ground level, or any other
location where employees will enter the Man Basket, to each location at
which the Man Basket is to be hoisted and positioned. This trial lift shall be
performed immediately prior to placing personnel on the Man Basket. The
operator shall determine that all systems, controls and safety devices are
activated and functioning properly; that no interferences exist; and that all
configurations necessary to reach those work locations will allow the
operator to remain under the 50 percent limit of the hoist's rated capacity.
A single trial lift shall be performed at one time for all locations that are to
be reached from a single set up position.
• The trial lift shall be repeated prior to hoisting employees whenever the
crane or derrick is moved and set up in a new location or returned to a
previously used location or starting of each day even in same location.
Additionally, the trial lift shall be repeated when the lift route is changed
unless the operator determines that the route change is not significant (i.e.
the route change would not affect the safety of hoisted employees.)
• After the trial lift, and just prior to hoisting personnel, the Man Basket shall
be hoisted a few inches and inspected to ensure that it is secure and
properly balanced. Employees shall not be hoisted unless the following
conditions are determined to exist.
Hoist ropes shall be free of kinks.
Multiple part lines shall not be twisted around each other
The primary attachment shall be centered over the Man Basket.
The hoisting system shall be inspected if the load rope is slack to ensure
all ropes are properly stated on drums and in sheaves.
• A visual inspection of the crane or derrick, rigging, Man Basket, and the crane or
derrick base support or ground shall be conducted by a competent person
immediately after the trial lift to determine whether the testing has exposed
any defect or produced any adverse effect upon any component or structure.
• Any defects found during inspections which create a safety hazard shall be
corrected before hoisting personnel and depending on situation, another
trial may be taken.
• At each job site, prior to hoisting employees on the Man Basket, and after
any repair or modification, the Man Basket and rigging shall be proof tested
to 125 percent of the Man Basket’s rated capacity by holding it in a
suspended position for five minutes with the test load evenly distributed on
the Man Basket (this may be done concurrently with the trial lift). After
proof testing, a competent person shall inspect the Man Basket and rigging.
Any deficiencies found shall be corrected and another proof test shall be
conducted. Personnel hoisting shall not be conducted until the proof testing
requirements are satisfied.
rd
• A valid 3 party test of the man basket should be mandatory.
10.8. Work Practices
• Employees shall keep all parts of the body inside the Man Basket during
raising, lowering, and positioning. This provision does not apply to an
occupant of the Man Basket performing the duties of a signal person.
• Before employees exit or enter a hoisted Man Basket that is not landed, the
Man Basket shall be secured to the structure where the work is to be
performed, unless securing to the structure creates an unsafe situation.
• Tag lines shall be used unless their use creates an unsafe condition.
• The crane or derrick operator shall remain at the controls at all times the
crane engine should be running during Man Basket is occupied.
• Hoisting of employees shall be promptly discontinued upon indication of any
dangerous weather conditions or other impending danger.
• Employees being hoisted shall remain in continuous sight of and in direct
communication with the operator or signal person. In those situations
where direct visual contact with the operator is not possible, and the use of
a signal person would create a greater hazard for that person, direct
communication alone such as by radio may be used.
• Except over water, employees occupying the Man Basket shall use a body
belt/harness system with lanyard appropriately attached to the lower load
block or overhaul ball, or to a structural member within the Man Basket
capable of supporting a fall impact for employees using the anchorage.
When working over water, the requirements of
Employees working over or near water, where the danger of drowning
exists, shall be provided with Indian Coast Guard‐approved life jacket or
buoyant work vests.
Prior to and after each use, the buoyant work vests or life preservers
shall be inspected for defects which would alter their strength or
buoyancy. Defective units shall not be used.
Ring buoys with at least 90 feet of line shall be provided and readily
available for emergency rescue operations. Distance between ring
buoys shall not exceed 200 feet.
At least one lifesaving skiff shall be immediately available at locations
where employees are working over or adjacent to water.
• No lifts shall be made on crane's or derrick's second load lines while
personnel are suspended on a Man Basket.
10.9. Traveling
• Hoisting of employees while the crane is traveling shall be prohibited,
except for portal, tower and locomotive cranes, or where the employer
demonstrates that there is no less hazardous way to perform the work.
• Under any circumstances where a crane would travel while hoisting
personnel, the employer shall implement the following procedures to
safeguard employees.
Crane travel shall be restricted to a fixed track or runway
Travel shall be limited to the load radius of the boom used during the
lift. The boom shall be parallel to the direction of travel.
A complete trial run shall be performed to test the route of travel
before employees are allowed to occupy the platform.
If travel is done with a rubber tired‐carrier, the condition and air pressure
of the tires shall be checked. The chart capacity for lifts on rubber shall be
used for application of the 50 percent reduction of rated capacity.
10.10. Pre‐lift meeting (Tool Box Talk before Man Basket Operation)
• A meeting attended by the crane or derrick operator, signal person(s) (if
necessary for the lift), employee(s) to be lifted, and the person responsible
for the task to be performed shall be held to review the appropriate
requirements and the procedures to be followed.
• This meeting shall be held prior to the trial lift at each new work location,
and shall be repeated for any employees newly assigned to the operation.
However, for men basket use maximum permissible wind speed is up to 25
km/Hr. (13.5knots) but for large boom length if basket observes swing even at
15.5 Km/ Hr. man basket lift can be suspended.
Refer Attachment 06‐ Sample Man Basket
Refer to 10080‐1‐HSEF‐DWP‐CN‐052, Elevating Work Platforms, Aerial Lifts, and
Material / Personnel Hoists.
10.11. Controlled Load Lowering (CLL) attachments for specific type of cranes
Controlled Load Lowering (CLL) is a mechanism provided on Crawler Cranes to
achieve gradual lowering of Load (Hook) in a controlled manner. This shall be
provided. (This is achieved by providing special mechanisms, like planetary
system or separate reduction achieved via chain and gears, in power train of
Hoist Lowering).
CLL is exactly opposite to the FREE FALL mechanism, possible on Cranes, wherein
the Hook is allowed to come down freely with the aid of gravitational force. As
the name ‘free fall’ clearly suggests, it does not have control in lowering of
Hook, except by applying brakes. And hence ‘free fall’, strictly, not to be used on
any crane. However it is excempted from cranes engaged in piling operation
with prior approval of P&M.
11. Training/Validation/ Licensing/Evaluation
11.1. Crane Operators
Operators of cranes must be trained and experienced. Operators shall successfully
complete a assessment/testing/validation program by P&M department. Testing
program may be a written test and an operating test demonstrating proficiency in
handling the specific type of crane. Normal and emergency operations,
load/capacity chart use, and crane signals shall be covered by the testing.
Refer Attachments 01, Crane Operator Training and Validation.
To operate a crane; employees must at a minimum:
• All crane operators shall have valid heavy motor vehicle (HMV) license
issued by Regional Transport Office (RTO) and safe driving permit (SDP)
issued by RIL traffic security cell.
• Be mentally alert and possess the physical ability to drive a motor vehicle
safely.
• Display a responsible attitude and be of a minimum age of 25 years
• Have completed validation of ability to operate that specific crane through
P&M department. (Refer to Application for Designated Driver, Form 10080‐
1‐ HSEF FMT‐CN‐014 or equal).
• Operator Record should be kept in 10080‐1‐HSEF‐CHK‐CN‐040 Crane
Operator License Record.
• Mobile crane operators shall pass a medical examination once every year by
a hospitals recognized by OH&FWC and contract cell of J3 Program. Physical
defects or emotional instability that could be a hazard to the operator or
others may be cause for disqualification.
• The mobile crane operator must be able to read and understand English.
Contractor supervisor will also assist the operator to understand crane
operations and rigging requirements.
• The mobile crane operator should have sufficient knowledge for reading
load chart, rigging plans (critical lift wt. > 15 Ton , multi crane lift ).
• The mobile crane operator will inform his supervisor and Heavy equipment
engineer if anyone is not in working condition. (i.e. Anti‐two blocking, SLI).
• Equipment owner / Contractor after delivering the required training, should
maintain the training/validation records for traceability for operators of the
lifting equipment.
• The operator must able to interpret the crane's actual net capacity for every
possible configuration of the machine.
• The mobile crane operator should have sufficient knowledge for reading
load chart, rigging plans (for critical lift wt. > 15 Ton or threat, multi crane
lift, (operator knowledge for rigging plan should be limited to heavy duty
crane i.e. 200T and above tire mounted or 350T and above crawler crane).
For Evaluation of operators skill following forms or equipment type forms to be
used;
• 10080‐1‐HSEF‐CHK‐CN‐089 Crane Operator Skills Test / Performance
Evaluation (Friction)
• 10080‐1‐HSEF‐CHK‐CN‐090 Crane Operator Skills Test / Performance
Evaluation (Hydraulic)
• 10080‐1‐HSEF‐CHK‐CN‐091 Crane Operator Skills Test / Performance
Evaluation (Tower)
• 10080‐1‐HSEF‐CHK‐CN‐092 Crane Operator Skills Test / Performance
Evaluation (Bridge / Overhead)
• 10080‐1‐HSEF‐CHK‐CN‐093 Crane Operator Skills Test / Performance
Evaluation (Drum Hoist)
An employee must carry state / country driver’s license and SDP while operating
crane and must display it upon request to authorized persons:
• The Contractor's HSE Representative must be advised of any change in the
status of such license and endorsements (such as cancellation or suspension).
• The employee will not operate crane on or off the project / site after state /
country driver's license is suspended, revoked, or otherwise affected.
11.2. Qualified riggers
• Rigger should be validated for rigging trade skill by P&M.
• He should know the weight of the load, how to select the appropriate
rigging for the load. And the differences between hitching configurations
and different application of belt sling, able to interpret rigging set up and
plan, lifting tools and tackles etc.
• Understand the concept of center of gravity and balancing of the load.
• Will use only lifting tool which are tested and of appropriate capacity as
prescribed in checklist, he should physically checked all lifting tools before
use.
12. Rigging Points of Contact
As a minimum, one rigging point of contact will be designated by the contractor
for each site/area and will perform the following:
• Ensure that required permits and procedures are in place and are being
adhered to during hoisting and rigging operations.
• Ensure that rigging equipment to be used has the required inspections per
this procedure.
• Ensure that J3 Program supplied lifting equipment, tools and tackles are
tested / retested as per schedule.
• Ensure that employees performing hoisting and rigging operations have the
required training and (as appropriate) certifications, validation and that
each has been documented properly.
• Assist in determining what hoisting and rigging operations should be
considered "critical lifts."
• Assist in preparing plans for critical lifts.
• Assist in planning and execution of all hoisting and rigging operations.
13. Procurement and Hire
Procurement and hire specifications for crane and rigging equipment must
include details such as type, load capacity, mode of operation, and materials to
be used. J3 Program PMT and P&M will establish the specifications.
A review must be conducted before placing a procurement request in order to
verify that equipment is suitable for the intended duty.
Vendor boom trucks should only be used for the purpose for which the
manufacturer designed the equipment.
Note: Anti‐Two Block System and Safe Load Indicator(SLI) is a mandatory
requirement for all types of cranes. SLI should be tested at least once in a year
and calibrated if needed. No lift should be carried out if SLI is not working.
14. Critical Lifts Permits, Risk Assessment and Lift Plan
Lifts excedding 85% of crane capacity loading, multiple crane lifts, complex or
heavy complex lifts (refer Section 5‐Definition ) require a Critical Lift Permit,
Form 10080‐1‐HSEF‐FMT‐CN‐028.
Note: Bridge cranes are exempted from the above requirement related to
permit and SLI .
• Any lift of 50 T and above shall be done in consultation and approval from
Heavy Lift department.
• Assessment Checklist filled for frequent/ repeated lifts at a single location
with same crane and its configuration can be valid for up to 2 weeks or on
discretion of J3 Program Lead Engineer and P&M Representative. However,
checking for compliance of set norms shall be ensured on daily basis to
account for any change in any of the assessment elements.
14.1. Mobile Crane Planning and Risk Assessment
An authorized crane user is required to complete the mobile crane planning and
risk assessment checklist before using crane. The mobile crane planning and risk
assessment checklist is included as Attachment 07.
14.2. Lifting Plan
For complex, heavy lift and super heavy lift ,for any lift exceeding 85% of
capacity loading of crane and multiple crane lifts, a lifting plan is required in
addition to the Mobile and hydra Crane Planning and Risk Assessment Checklist
and critical lift permit.
• Lifting plan will contain;
Plot plan details
Ground area preparation requirement.
Mobile cranes with type and capacity, type of lift with counter
weights. Crane hook weight
Weight and dimension of load.
Boom length and luffing angle.
Maximum and minimum load radius.
Crane capacity at maximum load radius
Spreader bar with size, weight and capacity
Slings size, capacity and its weight, included angle between
slings, Tailing plan shown in both plan and elevation drawing
Mobile cranes positions, marching with load.
Clearance from nearest equipment/structures for both load and
counter weights
Permissible wind velocity
Percentage loading of crane capacity etc.
• The Lifting Plan should be prepared by contractors authorized person,
rigging specialist and approved by J3 Program Area/Site /Construction
Manager, Lead engineer and P&M / Heavy Lift and reviewed by HSE.
• The lifting plan shall also include a detailed step‐by‐step description of the
whole operation, method statement, and state authorized person shall
supervise the lift.
14.3. Rigging scheme
Prepare rigging scheme for heavy and super heavy lifts, as required. The scheme
shall give details of total space/area requirement, plan / elevation of erection,
method statement, sequence of operation, rigging data, hook up details, etc.
14.4. Authorized Permit Issuer Training and Authorization
The appointment and training of Critical Lift Authorized J3 Program Permit
Issuers is similar to Permit to Work and Confined Space Entry Authorized Permit
Issuers (refer to 10080‐1‐HSEF‐ DWP‐CN‐016). However, in addition, they will
have sound and thorough knowledge in matters relating to the preparation and
conduct of critical lifts. Practical experience in preparing critical lift permits
under guidance will be an integral part of training. Appointment is made in
writing; on Form 10080‐1‐HSEF‐FMT‐CN‐025, Authorized Permit Issuers, by the
J3 Program Area/Site Manager.
Note: When performing a critical lift inside an operating facility, it is a common
requirement to use the facility “permit process” instead of the process described
above.
15. Assembly / Disassembly, Inspections, Tests, and Maintenance of
Cranes
15.1. Inspection and Testing of Equipment and Tools‐Tackles
• Initial Load Test: It is the responsibility of the manufacturers to carry out
examination in their respective workshops.
• Operational Test: Load test of mobile cranes shall be ensured by P&M at the
arrival to site. After approved load test, the hired crane should be deployed.
• Rated Load Test: In case of any repair or alteration to cranes, it shall be
examined by a competent person for rated load before putting them in use.
• Periodic Inspection: It is the responsibility of P & M Departments to ensure
periodic inspection for all cranes. Inspection will be done at least every 6
months.
• Periodic Examination: All cranes, Suspended Personnel Platform, Chain
pulley blocks and all lifting tools and tackles shall be thoroughly examined
by a competent person at least once in twelve months and a record of such
testing is to be maintained in Form No 10. P&M and MTT Departments shall
line up testing and certification agency for cranes and lifting tools tackles.
Only inspected, tested and validated (by competent agency authorized by
Reliance/J3 Program) shall be used.
• In case of rejection of any lifting tools tackles or machinery during testing by
competent persons, same shall be clearly mentioned on them. Web sling shall
be marked with "Rejected" by permanent marker and wire rope slings shall be
embossed with alphabet "R" on its ferule to distinguish rejected slings.
15.2. Rigging Equipment
A mothly inspection register of all rigging equipment (Form 10080‐1‐HSEF‐CHK‐
CN‐028, Rigging Equipment Register or equal) must be maintained at the site by
the contractor rigging inspector/ competenet person. Maintenance records
should also be avilable for review.
Clamps and lifting beams will be clearly labeled with the load capacity. Slings,
chains, hooks, and shackles will be tagged ,marked with the load carrying
capacity and colour coded as per yearly code scheme.
Rigging equipment will receive a daily preuse inspection by the operator and
rigger. Rigging equipment will be inspected periodically fortnightly/monthly by a
Competent Person nominated by the contractor. Periodic / monthly inspections
will be documented on Form 10080‐1‐HSEF‐CHK‐CN‐026, Monthly Inspection
Report – Construction Equipment and Light Vehicles or equivalent.
Periodic inspection should be done in accordance with Vendor/manufacturer’s
recommendations.
Inspection and maintenance forms/checklist are included as Attachment 09 for
daily inspection / fortnightly/monthly maintenance of different types/models of
cranes and equipments.
Rigging equipment that is worn or damaged to such an extent that, in the judgment
of a Competent Person, it cannot be repaired satisfactorily, must be destroyed by
cutting, and the lifting equipment register (Form 10080‐1‐HSEF‐CHK‐ CN‐028,
Rigging Equipment Register or equal) amended accordingly.
15.3. Assembly / Disassembly
Cranes received for use (through purchase, contract obligations, or rental) must
be assembled / disassembled in accordance with the manufacturer’s
instructions, recommendations, limitations, and specifications. Cranes should be
load‐tested in accordance with the manufacturer’s specifications and limitations
following the in country regulations . Any permit requirment in Assembly /
Disassembly will be approved by P&M.
15.4. Erection location and approach route
• Select suitable location at site to position crane such a way that it is near to
load pick up and final placing locations.
• Decide and develop route for movement of crane and trailer carrying load.
Maintain sufficient road width, turning radius for crane and trailer carrying
loads/heavy loads.
• All super heavy lift cranes shall preferably be escorted by traffic security.
15.5. Ground Preparation
• Free ground from water logging. Never allow water logging.
• Find out ground pressure exerted by the selected crane from crane
manufacturer/experts.
• Find out the ground bearing capacity of working location and if it is less, use
compact soil and steel plate to strengthen the same.
• Maintain required road slope for movement of crane and trailer as per
manufacturer’s/transporter’s recommendations.
• Spread a sand layer of minimum 2 inches thick under steel plate for even
load distribution. Maintain top of steel plate in level without any slope.
• Develop required area/space around crane as required for the movement of
assisting crane if assembly of crane is done at work location.
• Develop required area around lifting crane for movement of trailer carrying
load to be lifted and for tailing crane movement.
• Check out the surrounding obstructions such as structure, equipment,
piping, over head power lines, etc. Keep a minimum safe distance as
recommended by crane manufacturer and as applicable.
15.6. Crane Placement
• Place the crane in the required location.
• Check that the required radius with load is clear from other structure,
vessel, pipeline, overhead power line etc.
• If it is tyre mounted crane, use wooden block to support the base of fully
extended outriggers. Check with level for its leveling.
• After setting crane and loading counter weight, take boom up to minimum
radius and slew crane boom with counter weight slowly, 360 degree, step by
step, to check any settling of ground under outriggers or crawler.
• Remove crane immediately if any settling found and rectify ground. Check
availability of planned boom length, capacity, and hook‐blocks with crane
prior to lift.
• Check reach, interference with surrounding of boom, and actual capacity
available prior to lift by a mock up.
• Do not position crane on loose soil or sandy area without proper ground
preparation.
15.7. Lifting and placement of load by crane
• Free load from adhesion prior to loading crane. Hold load in plumb. Avoid
dragging load sideways as it will damage boom/jib or topple crane.
• Balance load at ground prior to taking it to its final position such as vertical
spools on columns/vessels, etc.
• Use sufficient guide rope to guide load during lift operation as required.
• Lift load and place it on its final setting location. Do initial tightening of bolts,
welding as applicable.
• Check verticality by theodolite, piano wire, or other instruments. Accept as
per specification and standard.
• Remove lifting gears by an assisting crane with a certified man basket or by
any other safe method.
15.8. Safety Precautions during the use of Crane
• Don’t perform lifting operation if wind velocity is more than 36 km/ hr.
• Don’t carry out any lift if visibility is limited by heavy rain, fog, low lighting
etc.
• Avoid heavy lift operation in night hours. However in case any night heavy lift is
required a hazard assessment must consider detailed planning, work hour,
time schedule, illumination, rain or environmental conditions and
communication limitations.
• Don’t allow wheels of hydraulic crane to touch the ground while in use.
• Check condition of crane along with operator, competent person and crane
experts. Any visual damage or oil leakage with crane identified report to
concerned personnel of Contractor and J3 Program PMT for corrective
action prior to use.
• Check the availability of Load Chart, Supplier’s Instruction Manual, and
Crane Load Test certificate, Daily Checklist, Maintenance History, Crane
Periodical Inspection and Testing Report.
• Don’t use mobile crane for transport of load for long distance. For short
distance transport within the same site, with use of guide rope.
• Lower the load with crane power. Don’t allow free fall of load.
• When traveling with a load, Competent Person must supervise the operation
• Speed of the crane on the construction road to be restricted up to 10Km / hr.
• Transportation of persons with crane is prohibited. At a time only driver and
helper are permitted.
• In case of blockage of road due to crane movement on main roads, keep fire
and security informed.
• Proper warning signals like red flag and lights shall be highlighted on all the
sides of the crane to guide nearby traffic.
• While in transit, ensure that boom is carried in line with the direction of
motion. The boom or jib must be hooked on crane body.
• When it is necessary to travel around a location with an extended jib, the
distance must be short and a competent attendant/supervisor must
accompany the crane and assist the crane operator.
• Don’t use the crane for dragging the load in horizontal plane.
• Ensure at least three windings of ropes always available on the rope drum.
• Lift compressed gas cylinders only in cradle.
• While hoisting equipment is in operation, the operator should not leave his
position.
• When parking crane, always use the brake.
• The mobile crane shall be fitted with suitable horn, reverse horn, headlights,
side lamps, rear and stoplights and flashing indicator.
• Refueling should not be done while the engine is running.
15.9. Inspections
Pre site inspection: Mobile cranes shall be inspected by a competent person(s)
from P&M department prior to use on J3 Program referred as Pre site Inspection
results will be documented on Form 10080‐1‐HSEF‐CHK‐CN‐058, Pre
Mobilization Inspection Report ‐ Construction Equipment and Light Vehicles or
equal. The initial inspection is valid for as long as the mobile crane remains on
site (site include P&M parking and maintenance area – except if idle. If the crane
leaves the J3 Program site, it must be re‐inspected if it returns irrespective of the
time away from the site.
Cranes will receive a daily preuse inspection by the operator. Cranes will be
inspected periodically (at least once in a month) by a Competent Person
nominated by the contractor. Daily inspections will be documented on Form
10080‐1‐HSEF‐CHK‐CN‐094, Daily Inspection Report ‐ Cranes (or equal if
developed refer attachment 09), and Periodic / monthly inspections will be
documented on Form 10080‐1‐HSEF‐CHK‐CN‐026, Monthly Inspection Report –
Construction Equipment and Light Vehicles and Cranes or equivalent.
Inspection and maintenance forms/checklist are included as Attachment 09 for
daily inspection / fortnightly/monthly maintenance of different types/models of
cranes.
A copy of the inspection report should be sent to the Construction Area/Site
office, a copy retained by the inspector and a copy retained in the cab of the
crane in a plastic wallet to protect it from damage. All inspection reports should
be in English and must be legible.
Periodic inspection should be done in accordance with Vendor/manufacturer’s
recommendations.
Qualified Persons will conduct and document “periodic” , “severe service,” and
“equipment not in regular use” (idle for 30 days or more) inspections. Designation
of Competent and Qualified Persons must be documented by contractor/ P&M in
accordance with 10080‐1‐HSEF‐DWP‐CN‐005, HSE General Requirements.
When brought onto site, each crane must have a copy of its last annual crane
inspection as per regulatory requirments by Goverment aproved competent
person. In a case by case basis If the last annual crane inspection as per
regulatory requiremets is not available, a thoroughly inspection will be
performed and recorder by P&M competent person.
In addition, cranes idle for greater than 30 days must receive inspection before
placing into operation to verify that there are no mechanical defects or safety
deficiencies; results will be documented on Form 10080‐1‐HSEF‐CHK‐CN‐058,
Pre Mobilization Inspection Report ‐ Construction Equipment and Light Vehicles
or equal.
Cranes that are idle for any length of time greater than 6 months must receive
an periodic [annual] crane inspection by a Goverment aproved competent
person prior to the equipment returning to service to verify that there are no
mechanical defects or safety deficiencies.
If the crane warrants service or repair, it will be rejected (before unloading /
use) and returned to the lessor or owner. The lessor / owner will be notified
before such action and, if possible, be allowed to make necessary repairs at his /
her own expense. J3 Program PMT /P&M Representative and the HSE
Representative will be part of this decision‐making process when major repairs
are required. A photocopy of the inspection report, noting all deficiencies will be
transmitted to the lessor / owner.
Annual inspections will be documented on a form specified by in country legal
requirment. Deficiencies must be fully explained in the “Remarks” section of the
form. Corrective actions also must be noted on the form before cranes are used
in the field.
If a deficiency has the potential for causing bodily injury to the operator / driver or
ground employees, the crane must be tagged in an obvious location (i.e. door
handle, steering wheel) with a Danger – Don’t Use It – Unsafe Tag, Form 10080‐1‐
HSEF‐FMT‐CN‐062 or equal, to avoid operation. The supervisor must be notified
when the crane is tagged out of service.
J3 Program PMT field engineers will ensure that contractors are conducting
daily/monthly inspections of rigging equipment, cranes and records are
maintained.
The followings will be foremost but not limited to criteria for periodic inspection
• Inspect the entire crane for structural damage. Be careful to check for
distortion or cracks in main frame, outrigger assemblies, and structural
attachments of the upper works to the carrier
• Inspect all welded connections for cracks. Inspect the main chords and
lacings and other structural items for paint flaking and cracking which may
indicate potential failure, as well as for dents, bends, abrasions, and
corrosion. Check hydraulic booms for bending, side sway, or droop.
• Check for deformed, cracked, or corroded members in the load/stress bearing
structure. Magnetic particle or other suitable crack detecting inspection should
be performed at least once each year by an inspection agency. Inspection
reports should be requested and retained in the crane file.
• Inspect cracked or worn sheaves and drums.
• Inspect for worn, cracked, or distorted parts such as: pins, bearings, shafts,
gears, rollers, locking devices, hook roller brackets, removable outrigger
attachments lugs, and welds.
• Inspect for excessive wear on brake and clutch system parts, linings, pawls,
and ratchets.
• Inspect all indicators, including load and boom angle indicators, for proper
operation and calibration.
• Inspect all power points for proper operation.
• Inspect for excessive wear on drive sprockets and/or chain stretch.
• Inspect for correct action of steering, braking, and locking devices.
• Check that the counterweight is secure.
• Check that the identification number is permanently and legibly marked on
jibs, blocks, equalizer beams, and all other accessories.
• Inspect all hydraulic and pneumatic hoses, fittings, and tubing. Any
deterioration of any system component should cause the inspector to
question whether further use would constitute a safety hazard. Conditions,
such as the following, require replacement of the part in question:
Any evidence of oil or air leaks on the surfaces of flexible hoses or at the
point at which the hose in question joins the metal end couplings.
Any abnormal deformation of the outer covering of hydraulic hose,
including any enlargement, local or otherwise.
Any leakage at connections which cannot be eliminated by normal
tightening.
Any evidence of abrasive wear that could have reduced the pressure
retaining capabilities of the hose or tube effected. The cause of the
rubbing or abrasion must be immediately eliminated.
• Tests ‐ Load and functional testing must be performed as follows:
A long radius, full‐capacity functional load test boom must be
performed by J3 Program P&M to verify that:
Safe Load indicating devices should be accurate and shall be
working properly with allowable tolerance.
Overload function for drum is working properly and will cut off
when the maximum radius is reached for the load being lifted
Boom will telescope in and out. Boom up and down under a
capacity load. The telescoping function is not required if the
manufacturer prohibits its use for the particular boom length and
boom angle being used.
Brakes release smoothly and are capable of holding the load
stationary.
Crane is stable at the maximum operating radius.
Crane can perform designed multi‐function operations such as
swing, hoist, boom and steering of the crawler crane.
Operator is knowledgeable / proficient and familiar with the
machine, including the safety systems, and is fully capable of
reading and understanding the load charts.
The long radius functional load test must be performed by picking a
known load in a direction or area that provides minimum risk and
booming down while holding the load 0.3 meter (1 foot) above grade
until the crane reaches maximum capacity and then booming back to
the original position.
Note: Booming out is not allowed in telescopic cranes with load
The test weights used in the above testing must be calibrated to known
load used in above testing to plus or minus 5 %.
Both the load block on the main hoist line and the overhaul ball on the
whip line must be raised to maximum height to ensure that the anti‐
two‐ block device will either warn the operator of the limit of hoisting,
or will cut out the hoisting function.
• Certification Sticker ‐ After the crane has passed the inspection as outlined
above, a certification sticker must be displayed on the crane, signifying
approval to perform work. The stickers preferably are color coded. Stickers
are issued with a validity of maximum six months. Refer to Attachment 08,
Certification Stickers, of this specification for an example of a certification
sticker. The operator must verify that all safety systems are working
properly and conduct daily inspections. Any deficiencies must be
immediately reported to the J3 Program PMT Lead Engineer and Contractor
rigging engineer/supervisor and P&M.
15.10. Operator's cab or cabin
Operators cabin should following should be provided with;
• A suitable seat belt for driver, a foot rest and protection from vibration;
• Necessary access to working parts in cab;
• Adequate protection against the weather;
• Adequately ventilated; and
• A suitable fire extinguisher.
Refer to Attachment 04, Safety Device Requirements, for a list of minimum
safety equipment / requirements.
15.11. Hooks
Crane hooks must be made from either forging or casting (steel or alloy) that has
been quenched and tempered and be fabricated as per manufacturesrs
specifications.
The test certificate or documentation specified above must be provided for each
hook stating the Working Load Limit (WLL) as specified by the manufacturer. The
hook must be stamped and colour coded as per yearly colour schme or
otherwise identified and be traceable to the certification / documentation.
A visual inspection and dimensional check must be performed on all crane hooks
before they are initially put into use. For new cranes, a manufacturer’s data sheet
showing the safe working load and the full dimensional details of each hook,
including throat opeening, must be provided to J3 Program MTT department / P&M.
All crane hooks must undergo magnetic particle or dye penetrant testing by
manufacturer before they are initially put into use on any J3 Program jobsite. If test
information is not normally provided by the manuafacturer, a P&M
competent person may advise on the test examination to be carried out
(magnetic particle / dye penetrant testing or X rays.)The tip of the hook block
should have a spring loaded safety latch.
15.12. Lift Lugs and Attachments
Lift lugs must be inspected before the lift. The inspection should include the
following:
• The size and quantity of all components must be checked, making sure that
all parts, such as gussets and reinforcing plates, have been installed
according to drawings.
• The location and orientation of lifting attachments must be checked for
conformance to drawings and specifications.
• Attachment welds for lifting lugs must be inspected for conformance to
drawings.
• Any damage or nonconformity noted must be brought to the attention of
the J3 Program PMT and rigging supervisor.
15.13. Slings/Rope
Safety Precautions for the use of wire Ropes and Slings
• Ensure that the correct rope / sling is in use. i.e. SWL of rope / sling.
• Clean and apply diesel or used oil lightly to prevent the slings from rusting.
• Inspect regularly for broken strands.
• Do not coil the slings as far as possible.
• Do not drag the slings on dirt or roads.
• Do not use them without proper packing in sharp corners.
• Do not use them at less than the prescribed included angle.
• Do not overload or subject ropes / slings to shock load.
• Follow proper method of securing dead end of wire rope when using a
wedge socket i.e. the dead or short end of rope should have a clip attached
to it or be looped back and secured itself by a clip.
• Do not attach the dead end of rope to the live side of the rope with a clip
when using a wedge socket as this will seriously weaken the attachment.
• All slings must be tested in accordance with in country regulations and
tagged, marked with the load carrying capacity and colour coded as per
yearly code scheme.
• No chain or wire rope with a knot shall be used at site.
• All slings must have a third party test certificate showing that they have
been proof tested to as per legal requirements, stating the safe working
load, size, and identification.
• All wire rope slings must be manufactured using a Flemish eye mechanical
connection to form he sling eye. Crimped fold over eye connections are
strictly prohibited.
Flemish woven mechanical eye
Crimped eye wire rope sling X
• Components of the loose gear, at the time of its use, are renewed if one of
its dimensions at any point has decreased by ten percent or more.
• A chain is withdrawn from use when it is stretched and increased in length
which exceeds five percent of its length or when a link of such chain is
deformed or is otherwise damaged or raised scraves of defective welds is
appeared on it.
• Rings, hooks, swivels and end links attached to a chain are of the same
material as that of such chain.
Slings/rope/fiber rope that do not meet the minimum requirements of in
country standards, legal requirments must be tagged; Danger – Don’t Use It –
Unsafe Tag, Form 10080‐1‐HSEF‐FMT‐CN‐062 or equivalent and rendered
unusable before the slings are removed from the project. For example, cut
through the lifting eyes on both ends of the sling
16. Maintenance, Repairs, and Recertification
Persons authorized to conduct maintenance and repair on cranes must meet the
criteria for, and be designated as, a Qualified Person in accordance with 10080‐
1‐ HSEF‐ DWP ‐CN‐005.
All maintenance and repairs shall be in accordance with manufacturer’s
recommendations. Maintenance of all cranes will be carried at a construction or
P&M site designated places.
Repairs to cranes and rigging, other than the replacement of parts, must be
carried out by the original manufacturer, the manufacturer’s agent, or a mechnic
approved by a Qualified Person. Any replacement part must be identical /
equivalent to the original part.
Appropriate recertification of a crane following repair must be accomplished
before the crane is placed back in service. Recertification is an inspection
equivalent to an annual inspection conducted by a Qualified Person.
Where load‐bearing components are repaired or replaced, rigging equipment
must be tested by application of a “proof load”/ applicable test to the
component as specified by a Competent Person, and then thoroughly examined.
A test certificate stating the working load limit / safe working load and the proof
load must be obtained. The test certificate and a record of the repair or
modification will be placed in the rigging equipment register.
Maintenance and repair of hired cranes will be done by agency owning the crane
and suseqently validated by P& M department.
Records of maintenance, repairs, and modification shall be maintained for three
years by RIL P&M department.
17. Modifications
No modifications or alterations that affect the capacity or safe operation of the
crane or rigging will be made by the project or any individual without the
manufacturer’s written approval. In case of alteration or modification designed
and fabricated in accordance with national or in‐country requirements by a
specialized vendor, the modified design must be pproved by the by J3 PMT and
P&M.
Modifications to cranes and rigging not affecting the capacity or safe operation
will be designed and fabricated in accordance with national or in‐country
standards, and the modified design approved by the by J3 program PMT and
P&M.
After modification, if a proof test is required by applicable standards, a test
certificate stating the WLL / safe working load and the proof load / Apllicable
test must be supplied by a Govt. Aproved Competent person .
18. Riggers / Rigging
18.1. Training
Attachment 02 describes typical qualification requirments based on OSHA
guidelines and best pratices in the construction industry. This can be referred to
establish J3 Program specific validation requirments.
18.2. Inspection
Riggers must ensure that newly purchased slings are properly marked, proof‐
load tested, and inspected.
User and Foreman will inspect wire rope and other rigging equipment
thoroughly before use on each shift. Include the following items as a minimum:
• Signs of damage or deterioration from prolonged use or misuse
• Missing components, identification, or load testing information
• Missing inspection tags or identifiers
Note: Any rigging equipment found defective or deficient in the above areas
must be tagged with a Danger – Don’t Use It – Unsafe Tag, Form 10080‐1‐HSEF‐
FMT‐ CN‐062 or equal, and returned for inspection and removal from service if
damaged.
Contractor Designated ‐ Rigging Inspector/competent person (Validated by PMT
Area/ Construction Manager) will inspect all wire rope and rigging equipment
each month. Records to be maintain in Form 10080‐1‐HSEF‐CHK‐CN‐028, Rigging
Equipment Register or equal .
Designation of Competent and Qualified Persons (validated by PMT Area/
Construction Manager ) must be documented in accordance with 10080‐1‐HSEF‐
DWP ‐CN‐005.
Inspection register will be used to document monthly inspections and contain
the following information, at a minimum:
• Equipment / Component Description or ID Number
• Inspector
• Date of Inspection
• Any defect identified and replacement etc.
19. General Safety Guidelines for Chain Pulley Blocks
• Before hanging the chain pulley block on the structure, ensure for its
adequate strength for structural member to withstand load.
• Don’t hang the block by tip of the top hook on structure.
• Ensure that chain pulley block are tested and certified.
• When a chain pulley block is hung to an overhead beam with a help of sling,
protect the sling against the sharp edges.
• The tip of the hook block should have a spring loaded safety latch. Pulley
blocks should have identification mark and SWL marked on them.
• Loads in excess of SWL should not be raised, lowered or suspended.
• The hand and load chains should hang freely without any knot or twist.
• The load should always be applied through seat of the hook. Side loading
will distort and damage the hook. Use hook chuck for this.
• Do not overcrowd the hook with multiple slings. A shackle connecting the
upper ends of sling legs can be put on the hook. This ensures vertical loading
of the hook.
• Do not drop, throw the blocks across the floor surface. If dropped
accidentally, get the block examined by a competent person before reuse.
• Chain pulley blocks are designed for lifting loads vertically and should not be
used for pulling horizontally or at an angle. Dragging or Pulling of load is to
be carried out by hook chuck only.
• Common misuses like hoisting person, lengthening load chain shall be
prevented.
20. Safety Guidelines for Winch
• Ensure load to be lifted is within the SWL of the winch.
• Select the correct winch to give required line pull.
• Ensure guards are provided for all moving parts of winch.
• Anchor the winch securely.
• Experienced and skilled operators only should operate the winch.
• Adequate warning signs shall be installed near the winch operating area.
• Ensure at least three windings of wire rope are available on the drum while
lifting / lowering the load.
• Ensure that the brakes of the wire rope drum are in working condition.
• Ensure that the pawl of the winch is working so that reverse movement of
the drum is prevented.
• Adequate protection should be provided to winch operator against
abnormal weather.
• Ensure that daily before use and periodic inspection are conducted.
• Winch shall be tested by Government approved competent person.
21. Air Tugger Operations / Pneumatic Hoist
(If Applies‐Equipment not in use regularly)
21.1. Equipment Inspection
A Competent Person – Air Tugger operator must inspect air tugger equipment daily
before use and at least quarterly (refer to Form 10080‐1‐HSEF‐CHK‐CN‐026).
Items to be reviewed will include anchorage, weight of items to be hoisted /
pulled, application of appropriate coefficients of friction, load capacity, and load
obstructions.
Air tuggers must be inspected daily by the crew foreman and tugger operator
before operation. Both employees will sign off on the daily inspection log
verifying said inspection (refer to Form 10080‐1‐HSEF‐CHK‐CN‐094 or equal).
21.2. Operator Qualifications
Operators must meet requirements equivalent to those required for crane
operators as specified Attachment 01.
Only certified operators may operate air tugger equipment.
21.3. Operations
A tugger plan, or Job Safety Analysis (JSA), will be prepared and submitted for
review and acceptance by the J3 Program PMT before operating a tugger, and
for each new configuration.
Each tugger location will also be reviewed after setup by the rigging point of
contact to ensure the following:
• Required access is available
• Setup is adequate for the intended loads (minimum 5‐to‐1 safety factor)
• Sign is posted identifying capacity of the tugger in its installed configuration
Loads to be lifted / pulled will be restricted to a maximum of 75 percent of the
rated capacity of the tugger and / or setup.
Only employees essential to the operation will be allowed to work near the
operating tugger, load line, and the moving load. A hard barricade must be used
to protect individuals from making contact with a tugger load line or machine.
i.e. employee walk way is with in 1.8 meters (6 feet) of the load line or the drum
Never use the tugger line for other than its intended purpose (such as tie‐off for safety
harness). Special care must be maintained during operation of the tugger to ensure the load
does not “hang up” causing the air tugger to be overloaded.
21.4. Lift Control Plan
All lifts / pulls must be documented on the tugger plan submitted for review and
approval by the rigging point of contact, and retained by the operator.
For each lift / pull, the operator must certify in the plan that:
• There are no potential interferences with tugger operation
• A substantial shield is installed to protect the operator from cable failure
• The lift area is properly barricaded
This plan will include the following critical elements of the lift / pull:
• Weight of the item being lifted
• Capacity of the tugger in the configuration it will be used
• Percent of tugger capacity, the combined weight of the load and rigging
represents
Supervision will periodically audit the lift logs for accuracy.