Procedure of Lifting Material, Equipment & Tools-PE11-3025-DOC-M1100

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Number:
PE11-3025-DOC-M1100 14 June 2012 28 September 2012 02 As Needed Page 1 of 15
WTP Improvement Project
Issued Date: Revision Date:
Procedure of Lifting Material, Equipment & Tools

Preparation: QA/QC Coord Authority: ODH Issuing Dept: QA/QC
Revision No. Next Revision: Page:
Contents
Contents ................................................................................................................... 1 1 INTRODUCTION .................................................................................................... 2 1.1 Background................................................................................................... 2 1.2 Purpose ........................................................................................................ 2 2 LIFTING PROCEDURES ........................................................................................... 2 2.1 General......................................................................................................... 2 2.2 Lifting plan.................................................................................................... 2 2.3 Load Balance and Stability.............................................................................. 2 2.3.1 Balance .............................................................................................. 3 2.3.2 Stability.............................................................................................. 3 2.4 The Load ...................................................................................................... 4 2.5 The Lifting Appliance (machine) And Lifting Gear ............................................. 4 2.6 The Site ........................................................................................................ 4 2.7 Procedure for Control of Heavy and Critical Lifts:.............................................. 5 2.8 Lifting Tubular Goods..................................................................................... 6 3 MOBILE CRANES .................................................................................................... 6 3.1 Lift Preparations: ........................................................................................... 6 3.2 Executing the Lift .......................................................................................... 7 4 HOISTS ................................................................................................................. 8 4.1 Selection of Hoists ......................................................................................... 8 4.2 Pre use examination and procedure: ............................................................... 8 5 USE OF LIFTING GEAR ........................................................................................... 9 5.1 Responsibility of Riggers ................................................................................ 9 5.2 Selection of Lifting Gear ............................................................................... 10 5.3 Shackles ..................................................................................................... 10 5.3.1 Wire Rope Slings............................................................................... 11 5.3.2 Webbing Slings ................................................................................. 12 5.3.3 Eye Bolts .......................................................................................... 12 5.3.4 Plate Clamps .................................................................................... 13 5.3.5 Beam Clamps ................................................................................... 14
PT. Envitech Perkasa
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1 INTRODUCTION
1.1 Background PT Envitech Perkasa carry out lifting operations to support activities such as construction, erection and commissioning. Lifting equipment used includes mobile cranes, winches and lifting gear. 1.2 Purpose The document provides direction and guidance for all personnel involved in lifting operation to plan and execute safe and effective lifting operations. This document defines procedures for lifting operations and criteria for selecting and using lifting equipment and lifting appliances.
2 LIFTING PROCEDURES
2.1 General Preparation of lifting operations shall include the operator, lifting supervisor following the checklist given in Appendix 1 to obtain written authorization from related party or the work site custodian to carry out the lifting operation. In addition lifting operations shall be covered by Valid (PTW) Permit to Work and Access Authorization at locations where these systems operate. 2.2 Lifting plan Prior to carrying out any lift a lifting plan shall be discussed and agreed by the equipment operators, riggers, banksmen and any other personnel involved in the lift. Potential hazards shall be identified and the plan shall identify the means to avoid them. 2.3 Load Balance and Stability Before lifting, it is essential to ensure that when clear of the ground, the load will adopt the intended attitude and remain securely attached to "the lifting machine" without overloading any part of the machine and lifting gear. This means that the load must be both balanced and stable.
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2.3.1 Balance For most lifts the load is required to be level when clear of the ground. To achieve this, the hook must be positioned vertically above the centre of gravity (C.G) the load. The legs of the sling(s) should be distributed as evenly as possible according to the lifting points available. The angle which each leg makes with the vertical affects the proportion of the load which will be imposed, so all legs should be, as far as practicable, at the same angle. If the load tilts on lifting, the loads in the sling legs will be unequal. This effect is especially significant when the angle between the legs is small. If a rigid load is lifted on four or more lifting points it may be found that only two or three legs take the majority of the load with the remaining legs providing a relatively small balance force. If this is the case, larger capacity slings will be required. 2.3.2 Stability In this context, stability means resistance to toppling. An object with a narrow base and high centre of gravity will need less force to topple it than one with a wide base and a low centre of gravity. As the height of the centre of gravity increases relative to the width of the base, a point will be reached where the object will fall over unless it is supported by external means. At this point, the object is regarded as being unstable. A similar situation exists with a suspended load. It is essential when slinging a load to ensure that it is stable. A load will be inherently stable if the lifting gear is attached above the centre of gravity and properly disposed around it. If the attachment points are below the centre of gravity the load will be unstable and addition supports or another method of rigging will be required. When it is intended to turn over the load in the air or position it at an inclined attitude, special consideration shall be given to the question of balance and stability to ensure that at all stages of the operation the load remains balanced, stable and securely attached without overloading. On occasions, particularly when using a single leg sling, it may be necessary to lift the load such as a pipe or drum with the sling positioned a short distance away from the centre of gravity. In such cases the load, when lifted, will take up a tilted position but will be inherently stable.
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2.4 The Load The load shall be assessed to determine the lifting plan including type of lifting appliance and lifting gear to be used. Assessment shall cover: Whether load is chemical or hazardous material The shape and number of pieces intended to lift at a time Whether load is self supporting or requires additional support Whether load has particular conditions that need to be taken into account i.e. fragile , hot , cold , corrosive or sharp Compatibility of lifting points with lifting gear. Weight of the load ( This is vital ) Center of gravity of the load before lifting. Whether the load is fixed down or free to lift. If it is fixed, will it be stable when the fixings are released or will it need support. 2.5 The Lifting Appliance (machine) And Lifting Gear Lifting appliances shall have a current valid Inspection / Test certificate in accordance with Client specification. The lifting appliance shall be positioned above the centre of gravity of the load. It must, in particular, be of sufficient Safe Working Load (SWL) and be able to move the load in a controlled manner to allow positioning. If a lifting point is to be used to be suitable it must also have sufficient Safe Working Load (SWL). Lifting gear shall have been inspected and marked with the current colour code in accordance with the ralated standard. It must have sufficient SWL to execute the lift. 2.6 The Site The site where lifting is to take place, shall be clear of obstructions including overhead power lines. Ground conditions shall be suitable to support and travel with the load (if applicable) There shall be a clear and safe path from the lifting site to the landing site. The landing site shall be level and strong enough to take the load. Beware of excessive floor loading, soft ground and hidden weak spots such as ducts and drains. Proximity of live process plant and other machinery is a particular consideration. The landing site may need preparation in which case this shall be done before the lift commences.
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The lifting plan shall also take account of any environmental factors i.e. temperature, moisture, wind etc. that may affect the operation. 2.7 Procedure for Control of Heavy and Critical Lifts: This clause specifies the minimum requirements to be met for the execution of heavy & critical lifts. Lifting operations are classed as heavy and / or critical if any of the following conditions apply. All lifts exceeding 100 Tonnes All lifts exceeding 75% of the rated capacity of Cranes in as rigged condition. All lifts requiring use of more than one crane simultaneously. All lifts involving equipment made of thin /fragile members susceptible to deformation during lifting Lifting in close vicinity of a live plant where lifting operation can endanger the safety of the plant. The lifting operation shall be planned and performed taking in account all the foreseeable risks. As a minimum the lifting plan should include the following: Verification of crane capacity versus load. Selection of lifting gear suitable for the operation. The characteristics of load and method of rigging for lifting. The position of crane and load, before, during and after the operation. To the scale, sketch shall be prepared, detailing the stages and sequence of operation. Relevant calculations supporting the safety limits of the operation considering effects of dynamic loading and weather conditions. Specific instructions for handling of equipment supplied by the manufacturer The ground conditions, and requirements for leveling and compacting, if necessary Clear identification and defining of responsibilities for various activities. A lifting team comprising site engineers, Lifting /Rigging superintendent, crane operator, rigger, banksman and a safety officer is essential for the operation. The crane operator shall not be placed in charge of the lifting operation
The following documents shall be prepared prior to undertaking the operation. 1. The Lifting plan covering all aspects of the lift. 2. Certificates for cranes, lifting gear, crane operator & riggers 3. Drawings/documents relating to equipment / load to be handled
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2.8 Lifting Tubular Goods Lifting of tubular sections (pipes) is a common lifting operation to which the following guidance notes apply When loading / unloading from a trailer the need for personnel to climb onto the load to position slings and hooks shall be avoided wherever possible. This shall be achieved through use of access platforms and load positioning to allow access between the headboard and the load. Personnel may only access the trailer etc on ladders that are correctly set up. All personnel shall dismount from the trailer after positioning slings and before lifting commences. Hooks are permitted to connect to the pipe ends only when they are of a type designed specifically for the purpose. Standard hooks are not acceptable since they will be subject to overstressing. When slings ( without hooks ) are used they should be positioned approx. 25 % of total length in from either end The slings should be doubled wrapped with a choke hitch taking care not to cross over the sling on the underside of the pipe or pipe bundle. The chock hitch should be pulled tight to secure the bundle. The included angle between the slings shall not exceed 90 degrees. Bundled pipe shall only be lifted using the correct slings designed to handle the load. Bundling straps shall not be used to lift the load. The slings supplied with pipe bundles from the manufacturer or stockist shall not be used for any purpose other than lifting of the bundles during transportation to the Company designated store or laydown areas. They shall be scrapped immediately after this use.
3 MOBILE CRANES
3.1 Lift Preparations: The crane operator shall be satisfied that site conditions are suitable to execute the lift. He should check the weight of the load against the crane capacity. The operator shall assess the radii at which the crane will be required to operate during the lift and consult the load charts to verify crane capacity to work under the load/radii combinations. He shall ensure the crane set up has an adequate number of wire rope falls to accommodate the load. All pre-use checks shall be completed and the lifting plan discussed and agreed between the crane operator, riggers and banksman.
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Outriggers shall be positioned so the crane is level with the wheels just clear from ground. The operator shall verify he can receive and send signals to the riggers and banksman. Hand signal communication shall be in accordance with standard hand signal requirement but during the actual lift signals shall be from a single banksman except for the emergency stop signal which may be given by any person. 3.2 Executing the Lift The operator shall position the hook above the center of the load and ensure the riggers attach the load correctly to the cranes hook. The operator shall keep the boom angle at 40 degrees or higher during the course of the lift. Following signals from the rigger, the load shall be hoisted approximately 300mm from the ground. At this point the operator shall cross check the reading on the load indicator with relevant load chart to ensure the load indicator is operating correctly. The riggers shall check the load to see that it will remain stable. If it looks unstable the load must be lowered to the ground and additional supports added. If the load is satisfactory, a tag line(s) shall be attached and the load traveled to the prepared landing site. The operator shall lowers the load to approximately 12 from the ground, when it shall be checked to see whether additional supports are required to land the load safely. The load can then lowered to the ground onto supports if necessary. The rigging tackle can then be removed and the banksmen shall give the shutdown signal. Cranes shall never be utilised for any purpose other than those it was designed to perform. Mobile cranes shall not be used to transport a load, Mobile cranes shall not be used when the wind conditions are more than 25 knots.
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4 HOISTS
4.1 Selection of Hoists Select the correct capacity Equipment of load intend to lift Select the correct and required Height of lift (Range of lift ) If the range of lift is more. Chain block can be used If the range of lift is short. lever hoist can be used Check the Anchoring and attaching point. If you have Runway beam, trolley as well as chain block can be used. Lack of Head room and confined space Check any obstruction that may impede the operation. Selection electric or pneumatic operated hoist depends on availability of power source Electric operated machines are hazarded than pneumatic operated. These are all used only for vertical lift. The operator must be trained to operate this kind of machine 4.2 Pre use examination and procedure: Check the required valid Inspection / Test certificate for the particular equipment Check the general conditions of the equipment Check the safety latch whether it is fitted or missing. If it is missing, dont use it. Know the operating mechanism of each equipment Check the condition of brakes and other safe locking systems Check the operating levers (Chains, Operating handle. Pawl and ratchet mechanism) Check there are no sign of misuse (stretched hook, cracked casing and distorted chains) Stretched hand chain or distorted operating lever could indicate previous overloading. It is essential to ensure that the structure from which a hoist is suspended is adequate for the load it is intended to carry.(it includes Hoist itself, Hook attachments, Sling, shackle , trolley etc) When using hook suspended hoists, the top hook should be attached to its supports in such a manner that the support fits freely into the seat of the hook and does not exert any side thrust upon the point. The top hook should be fitted with safety latch.
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After installation, checks should be made to ensure that the hand chain and load chain hang freely and are not twisted or knotted. The length of the load chain should be checked to ensure that the bottom hook will reach the lowest point required with out running the load chain fully out. If the load chain is permitted to run fully out, undue stress may be placed on the slack end anchorage (which is not a true load bearing component) The Operator be familiar with the equipment and the manufacturers instruction on its operation, maintenance and inspection. Ensure that Load rigging (i.e. Sling, shackles. Ring) correctly bowl of the hook and allow the safety latch to close. Ensure that the load is correctly balanced Ensure that all restrictions have been removed e.g. hold down bolts The Operators /users must wear the correct Personnel Protective Equipment (PPE) safety attire, coveralls, safety shoes, hard hat, gloves Use certified lifting loose gear for attachments DO NOT: Load the tip of the hook Use the load chain as a sling wrapped around items to be lifted and hooked back on itself Travel the load above the personnel Use excessive force on the hand chain or operating lever as this would result in over loading the equipment (chain block , lever hoist) Use the extension pipe on the lever for extra leverage (lever hoist) Never allow the lifting machine unattended with load. Never try to drag the load with lifting machine which is designed for lifting Never try to lift the load with pulling machine which is designed for pulling only. Drop and drag the lifting machine on the floor or deck
5 USE OF LIFTING GEAR

5.1 Responsibility of Riggers It is the riggers responsibility to ensure that the Lifting gear is functioning correctly, is safe to use, and properly maintained. They shall: 1. Check that the lifting gear is in good condition, certified for use, correctly colour coded, and of sufficient capacity to carryout the lift
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2. Ensure that Lifting Gear is marked or punched with I.D. Number , SWL and angle of lift 5.2 Selection of Lifting Gear Selection of lifting gear shall take account of: A. Load Characteristics: Size and Weight of the load Physical nature of the load (Chemical ,solid piece , pipe, vessel ,Electrical Item or machine) Attachments, Lifting points and supports Position of load whether it is vertical or horizontal Height and range of lift B. Site Characteristics: Temperature Limited space or head room Indoor or outdoor Refer to Appendices for SWL charts for various sling types, eye bolts and shackles 5.3 Shackles There are two types of shackles in general use: Dee shackle; and Bow shackle. Selection of shackles: Shackle shall be selected based on weight of the load and number of wires to be accommodated and or size of hook. Bow shackles are preferred if a number of wires are to be accommodated Shackles should be selected to suit the load being lifted allowing for any increased loading due to sling angle. The dimensions of the shackle will often be governed by the hole diameter and the thickness of the material of the lifting eye. If safety pin shackles are used, ensure split pins are fitted Screw pin shackles are preferred where frequent attaching and detaching of load Safety pin shackles are preferred where attachment to wire rope or load is permanent. Load should act on the centre of the pin and crown of body.
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Ensure that the sling eye fits into the body crown The shackle body should be able to swivel to accommodate inclined loads. Never use a shackle in such a manner that it will unscrew the shackle pin. Never replace the shackle pin with bolts Never weld on shackles
5.3.1 Wire Rope Slings There are two types of core used in wire rope construction. Steel core wire rope; and Fibre core wire rope. They can be Single Leg, and Multi-Leg. The end termination can be soft eye or thimble eye. Selection and Use of Wire Rope Slings: Select the wire rope based on the weight of load, number of hooks for attachment, no of items to be lifted at a time. Use of single leg sling is preferred where there is a single point hook or attachment. Use of multi leg slings is preferred where there are multiple lifting points (i.e. container, ) When using multi leg wire rope slings, included angle plays a major role, the SWL decreases with increase in angle. Ensure all the legs carry the same loading Fibre core wire ropes are preferred where flexibility is required in application Steel core wire ropes are more resistant to crushing l (Winch operation) The wire rope sling shall have current inspection current color code and I.D, SWL, Angle of lift clearly marked and visible. Select the suitable Effective Work Length (EWL) so that the included angle does not exceeding 90 degree. Never drag the sling across the floor Never drag sling out from under a load with crane Always use a softener when using the sling against a sharp object. Never repair the wire rope sling (Welding etc) Never knot a wire rope sling Never permit the sling angle exceeding the marked angle on the sling
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5.3.2 Webbing Slings Webbing slings are versatile and light weight and easy to handle and as such are commonly used but they are very susceptible to damage during use and if stored incorrectly. . There are two types: Round webbing sling; and Flat webbing sling (Belt) Selection and Use of Webbing Slings Webbing sling shall have current colour code and I.D, SWL, Safety factor clearly marked and visible. Prior to use, Webbing sling should be laid out in good light and examined over its full length and checked for damaged caused by sharp edged, Burning and scuffing ,contamination by chemicals, and damaged stitching. Sling shall be selected based on the weight of load and mode of lift (choke or basket hitch) The mode factor shall be used for calculating the SWL .i.e. straight lift M=1.0, choker hitch M=0.8, basket hitch with 0 degree M=2.0, basket hitch with 90 degree M=1.4 Generally the width of the flat webbing sling governs the SWL. By thumb rule, for simplex webbing sling 50 mm equal to 1.0 ton, for duplex webbing sling. 25 mm (1 ) equal to 1.0 tonne, 2 equal to 2.0 Ton. Sharp edges on the object can cause local cuts and tears. Special care shall be taken or use soft packing against sharp edges. Webbing slings are preferred over other types of sling where the object is susceptible to damage. Webbing Slings shall never be used in knotted or twisted condition Slings shall never be repaired. A damaged webbing sling or a sling with damaged cover shall be discarded and taken out of service. All Webbing slings shall be stored away from direct sunlight (to minimise the effect of ultraviolet deterioration) on a clean rack, away from any source of heat. Do not use a webbing sling in conjunction with a wire rope sling due to the mismatch in elasticity's. 5.3.3 Eye Bolts Eye bolts are commonly used for lifting equipment like motors, panel boards and pumps during maintenance work.
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There
are different types of Eye bolts: Dynamo eye bolt; Collar eye bolt; and Collar eye bolt with link.
Dynamo eye bolts are preferred axial loads are applied (Motors, pumps) Collar eyebolts and eyebolts with links are preferred where angle of lift is constant, as the collar and link bears all load. Selection and Use of Eye Bolts: Eye bolt shall be selected based on the weight of load and female thread on the equipment, number of lifting points and position of lift (straight or inclined). Eye bolts shall have current colour code and I.D, SWL clearly marked and visible. The thread of eye bolt and thread on the load shall be examined for wear, thread damage, wear on crown and deformation. SWL reduces as lift angle increases. Eyebolts should always be screwed down tight so that the collar is in full contact with the surface of the item being lifted. Shim washer shall be used to obtain full contact with the surface. If lifting with a pair of eye bolt, always use a two leg sling with hook , never use a sling in a basket form Never carry out alterations on eye bolts (welding or threading) Never pull the eye bolt in horizontal direction.
5.3.4 Plate Clamps Plate clamps are available in two designs. Horizontal plate clamp; and Vertical plate clamp Selection and Use of Plate Clamps: When selecting the clamps consider how the plate is to be transported and stacked ( i.e. horizontally or vertically) Consider the weight of the plate to be transported which will determine the SWL of the plate clamps Consider the plate thickness and Jaw opening
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The plate clamp shall have the current colour code, I.D, and SWL clearly marked and visible. Check for any obvious defects( Wear or stretch in crown on link, wear on jaw, any mal functioning of locking mechanism) Position the clamp over the edge of the plate and ensure that plate butts against the jaw stop Check the plate is clean and free from mill scale , dirt , oil and grease Lock the jaw in the closed position and ensure that the jaw has firm bite on the plate Use an adequate number of plate clamp to balance the load. Lift slowly to allow the jaw to obtain a good grip. Use a spreader beam to lift heavier plate. Never attach the clamp to the side of the plate Never lower the load fast, it could cause the clamp to release the plate Never lift horizontally with a vertical clamp and vice versa Never lift more than one plate at a time. 5.3.5 Beam Clamps Beam clamps provide a simple and portable means of attaching a hoist to a runway beam or lifting beam Beam clamps are available in two basic designs, the Clip on type and more popular adjustable type Selection and Use of Beam Clamps: Ensure the correct clamp is selected to suit the beam flange and the weight of the load to be lifted. The width of the beam flange must also be considered and may well lead to the selection of clamp in excess of desired SWL to be compatible with the beam dimensions. If the clamps are to be used to suspend a sheave block, the additional load caused by the down load pull on the effort rope must be taken into consideration. The beam clamp shall have current colour code and I.D, and SWL clearly marked and visible. Check the suspension shackle, load bar for wear , stretch, distortion Check the inner and outer clamps for wear ,distortion and cracking and jaws for deformation Position the beam clamps on the beam flange directly above the load to minimise the any angular loading.
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Hand tighten the clamp onto the flange by means of the tommy bar and ensure it has seated correctly Over tightening cause undue pressure on the clamp knuckles and can result in the clamp failing. Under tightening results in the load being transferred to clamp knuckle and can result in the clamp failing. Ensure the hoisting unit is correctly seated in the suspension shackle. Never subject the clamp to side loading Never overload the clamp

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PE11-3025-DOC-M1100 14 June 2012 28 September 2012 02 As Needed Page 1 of 15

WTP Improvement Project

Issued Date: Revision Date: