SHELL_SMEP Lifting and Hoisting Manual Rev. 1.0

Shell EP ASIA PACIFIC (EPA)

Production Directorate

SMEP LIFTING AND HOISTING MANUAL SMEP.EP200802258279 Code of Practice Business Control Document – Company Standard Restricted to Shell Personnel Only

Page 1 of 247

DOCUMENT HISTORY Custodian

William

MacDonald

Export Compliance Control No.

No US Content

Type

Business Control Document – Company Standard

REVISION CHANGE DETAILS REV.

Location

of Change

0.1

This document will be

Description

of Change

New Issue

maintained live on

the Shell EPA intranet site.

The web-based document

w i l l be t he co nt r ol l e d v er s i o n a nd r e v i s i o n a nno unce m e nt s w i l l be di s t r i but e d v i a e -m ai l t o relevant parties and p

ublished on the web.

Copies or extracts o

f this document, which

have

been downloaded from the website, are uncontrolled copies and cannot be guaranteed to be the latest version.

DISCLAIMER

The relationships shown in this document are for EPA Region organizational maintenance and planning purposes and are not intended to create legal or corporate authority incompatible w i t h o r s upe r s e di ng t he unde r l y i ng c or po r a t e g o v e r na nce a nd s t r u ct ur e o f par t i ci pa t i ng companies, including for example, authorities of the board of executive officers of any

particular company.

Page 2 of 247

directors, individual directors or

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

TABLE OF CONTENTS 1.0

PREFACE.

...................................................

Possible Reasons

1.1.1

Contributory

1.1.2

Operator

1.1.3

Equipment

Failure ................................................

....................................

1.1.4

Safe System of Work ............................................

....................................

1.1.5

Requirements of

2.0 2.1 3.0

Purpose

For Accidents

............................................15

1.1

..............................................

Factors .............................................

Error ................................................

a Safe System

.....................1

15

........................................

15 15 16

of Work. ..................................................

.....................................................

..... 16

............................................18

Scope ............................................

...................................................

..... 18

Certification

...................................................

........................................19

3.1

Introduction

....................................................

........................................19

3.2

Certification With New Lifting Equipment......................................................19

3.2.1

Inspection

Certificate................................................................................

3.2.2

Operating

and Maintenance

3.3

Certification of

3.4

Retention Period

3.4.1

Inspection Certific

3.4.2

Thorough Examination

4.0 4.1 5.0

Instructions

5

....................................

19

..................................................

..... 19

Existing Lifting Equipment..................................................... for Certificates an

d Reports.

19

...........................................

ates..................................................................

..... 19 .............

Certificates..........................................................

19

..... 20

Maintenance of Lifting Equipment................................................................21 Introduction

....................................................

........................................21

Marking of Lifting Equipment.............................................................

22

Requirements

5.2

W o r k i ng L o ad L i m i t ( W L L ) / Sa f e W or k i ng L o a d ( SW L ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

5.2.1

Safe Wor king Load (SWL)

5.2.2

W o r k i ng L o ad L i m i t ( W L L ) M a r k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

5.2.3

V a r i a bl e W L L o r S W L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

5.2.4

De-rating

5.2.5

Lifting

Equipment

assembly

5.2.6

Lifting

Accessory

Configurations

5.2.7

A cce s s o r i e s - O t he r F a ct o r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3

5.2.8

Lifting Equip

5.2.9

Gangways

5.2.10 6.0 6.1 7.0 7.1

..............................................

.........

5.1

Mark .............................................

...................................................

Equipment

ment for Lifting

............................................

Persons

Marking

Colour Coding

22

............................................

23

....................

23

.....................

23

...............................................

.............

23

................................................

.......................................................

Lifting Equ ipment C olour Codes ............................................. Lifting Equipment

.....................

....................................................

.............................................. Identity

............................................22

23

.............

23

.....................24

System ..................................................

..... 24

Training of Personnel...................................................................

.............

25

Training Responsibilities...............................................................

.............

25

Page 3 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

7.2

Training.................................................................................................25

7.2.1

A ddi t i o nal T r a i ni ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5

7.2.2

Training for New a

7.2.3

Personnel Under Training...............

7.2.4

Qualification

8.0

nd Inexperienced Personnel...............................................

Updates ...............................................

Planning, Definitions and

25

...........................................................

Execution of

. 25

................................

25

Lifts ..............................................

8.1

Purpose

8.2 8.3

Scope ............................................ ................................................... Responsibilities ................................................... ....................................26

8.4

Correct Use ............................................

8.5

Safety Margin .............................................

8.6

Controlling Access to the Lift Area...............................................................26

8.7

Risk Assessment

8.7.1

Lift Plan/JSA...............................

8.7.2

Risk Matrix .................................................

8.7.3

10 Questions For

8.8

Lift Categorisation

8.8.1

Routine

Lifts.......................................................................................

8.8.2

Routine

Lift .................................................

8.8.3

Non-Routine –

8.8.4

Non-Routine

– C OMPLICATED

8.8.5

Non-Routine

– COMPLEX

8.8.6

Non-Routine

– HEAV Y ...................................................

8.9

Execution

8.9.1

Permits ...................................................

8.9.2

Pre-lift Meetings (Toolbox Talk)...................

8.9.3

Conducting the Lifting Ope

9.0

.....................................................

..... 26

............................................26

................................................26 ............................................26

...............................................

........................................26

...................................................

.........

............................................

a SAFE Lift...................................................................... ...............................................

26 27 28

....................................28 ..... 28

............................................

SIMPLE............................................................................... .........................................

28 30

............................

...................................................

...................................................

Personnel

..... 26

........................ ............................

31 31 33

............................................33 ............................................... ................................................

ration............................................................

Lifting .................................................. .....................................................

33 33 ..... 33

....................................34

9.1

Purpose

9.2

Scope ............................................

............................................34

9.3

A ut ho r i ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5

9.4

Prerequisites

9.5

Objectives

..........................................

9.6

Procedures

.................................................

9.7

Defined

9.8

Emergency Conditions...............................................................................36

9.9

Risk Assessment

9.10

Other Considerations................................................................................37

9.11

Criteria..................................................................................................37

...................................................

...............................................

Cases .........................................

...............................................

Page 4 of 247

..... 35

............................................35 ................................................... ............................................36 ................................................36

........................................36

. 36

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

9.11.1

Crane Suitability

9.11.2

Personnel Transfer

SMEP.EP200802258279

MANUAL

REV.1.0

..............................................

....................................

37

Carrier......................................................................

37

9.11.3

V e s s e l S ui t a bi l i t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8

9.11.4

Take-off

9.12

and landing

Environmental

area ..............................................

.............................................

........................

38

............................................39

9.12.1

W e a t he r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

9.12.2

V i s i bi l i t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

9.12.3 9.12.4

Daylight ................................................. ............................................ Rainfall and Electrical Stor ms.............................................................

9.12.5 9.13

Communications Personnel

.......................................................

...................................................

9.13.1

Crane or Winch Operator...........................

9.13.2

Banksman

9.13.3

Assisting

9.13.4

........................................... Personnel

Personnel

............................

by Carrier

40

............................................40 ............................................

40

................................................

...................................................

Transferring

39 ..... 40

40

............................

.......................................................

40 ..... 40

9.14

Bags .................................................

9.15

Toolbox Talk .......................................................

9.16

Recovery

9.17

V e s s e l P r o pe l l e r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1

9.18

Planned Maintenance................................................................................41

9.19

A dm i ni s t r a t i o n a nd O pe r at i o na l D ut i e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1

Arrangements

SMEP Site Representative

9.19.2

Master of

9.19.3

Banksman and/or

9.19.4

Crane Operator............

9.19.5

Riggers/Deck

9.19.6

Personnel

9.19.7

Crane owner’s Requirements

9.19.8

9.19.10

...........................................

............................41

............................

42

the Vessel..............................................................................

42

Deck Foreman.............................................................. ...........................................................

43 .............

Hands.........................................................................

Transferring

General

..... 41

....................................41

.................................................

9.19.1

9.19.9

...............................................

Precautions

...............................................

............................

......................................................

..................................................

Trial Lifts ................................................

44

............. ............................

Pre-Use Inspection................................................................

43

..... 43

44 44

....................4 ............................................

9.20

Man Riding (drilling operations)

9.20.1

W i nche s f o r M a n R i di ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6

10.0

Suspended

Work B askets (Cranes)

10.1

Requirements

10.2

Equipment

10.3

Personnel

10.4

Personnel Engaged in Su

10.4.1

............................................

5 45

..................................................

.............................................. ..............................................

................................................... spended Work Basket

.....................4

5

.............

48

............................................48 ................................................48 ............................................48 Activities (Onshore Only)

.............

49

A ut ho r i t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9

Page 5 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

10.4.2

Prerequisites...................................................

10.4.3

Risk Assessment...............

10.4.4 10.5

Other Considerations

REV.1.0

....................................

.......................................................

49

.............

.......................................................

.....................

49 50

Criteria..................................................................................................50

10.5.1

Crane Suitability

10.5.2

W o r k B as k e t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0

10.6

Environmental

..............................................

Conditions

....................................

..............................................

50

............................51

10.6.1 10.6.2

W e a t he r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 V i s i bi l i t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1

10.6.3

Daylight

10.6.4

Rainfall

10.7 10.8 10.9

................................................. & Electrical

Communications

..................................................

Personnel

...................................................

Banksman

10.9.2

Personnel Working from the Work B

10.11

Toolbox Recovery

10.12.1

............................................

Maintenance

Talk...................................................................................

...............................................

53

Planned maintenance................................................................

.............

53

A dm i ni s t r a t i v e and O pe r at i o na l D ut i e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3

10.13.3

Crane Driver ...................................................

10.13.4

Riggers...................................................

10.13.5

Personnel Working

10.13.6

Crane Owner’s Requir

10.13.7

General

10.13.8

Carrier Pre-use Inspection

Charge.................................................................................. ...........................................

53

................................................ ....................................

Precautions

54 54

............................................

from a Workbasket...................................................... ements.................................................. ..................................................

Trial Lifts ................................................

54 55

................. ............................

Check ................................................

.............

............................................

55 55 56 56

Use of Mobile Cranes on Marine Vessels.......................................................57

11.1

Purpose

11.2

Scope ............................................

11.3

Requirements

11.3.3

.............

............................................53

Banksman

11.3.2

..... 52

Arrangements.............................................................

Person in

11.3.1

52

............................................52

10.13.2

10.13.9

52

asket..................................................

10.13.1

11.0

....................................52

............................................52

..............................................

Tool Bags ..................................................

10.11.2

10.13

51

Safety....................................................................................................52

10.11.1

10.12

51

.............

Crane...................................................................................................52

10.9.1

10.10

............................................

Storms .......................................................

.....................................................

............................................57 ...................................................

..............................................

Crane Suitability

..............................................

Types of Mobile Cranes................. Crane Capacity

....................................

.......................................................

................................................

Page 6 of 247

..... 57

............................................57

....................................

57 . 58 59

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

11.3.4 11.4 11.4.1 11.5

AND HOISTING

Crane Stability for Dec

SMEP.EP200802258279

MANUAL

REV.1.0

k Mounted Cranes.................................

.................

59

W e a t he r C r i t er i a and M o bi l e O f f s ho r e U ni t ( M OU ) S t a bi l i ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 W e a t he r C r i t e r i a A nd M obi l e O f fs ho r e U ni t S t abi l i t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 Mobile Cranes Tied-Down, Free

Lifting and Travelling With

Load .......................60

11.5.1

V e s s e l de ck St r e ngt h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0

11.5.2

Mobile cranes tied-down

11.5.3

Mobile c ranes free lifting

11.5.4 11.5.5 11.5.6

...............................................

Procedures

..............................................

Documentation

............................................

11.7

Periodic

General .................................................

11.7.2

Crane Pre-start

11.7.3

....................................62

Planned maintenance...................................................................

..... 63

............................................

63 .........

63

Fork Lift Trucks........................................................................................64

12.1

General

12.2

Pre-Use..................................................................................................64

.............................................

...............................................

..... 64

Start vehic le inspection.........................................................................

12.2.2

Ignition

12.2.3

Engine Running

ON checks ..................................................

12.2.4

Pre-use check

12.2.5

Documents

12.2.6

Hazardous

12.3

Operations

12.4

Capacity

13.1

62

............................................63

General .................................................

13

62

....................

incidents......................................................

...............................................

11.8.2

12.2.1

62

............................................

11.8.1

12

............. 61 ..... 62

............................................

Checks .....................................................

Reporting of defects and Maintenance

61

............................................62

Checks ...................................................

11.7.1

60

....................

Mobile c ranes travelling with load ............................................. Mobile cranes u sed for basket transfer .................................................

11.6

11.8

........................

..................................................

Checks .............................................

s for forklift trucks

not in use for an extended

............................................. Zone Requireme

64

............................

65

period of time

.....................................................

Requirements

66

.....................

66

........................................66 ................................................66

Mechanical Handling Equipment......................................................... General

....... 65

............................................

nts ............................................

................................................

. 64

............................

.........

...................................................

67

............................67

13.2

A e r i a l P l at f o r m s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7

13.3

Design Criteria

- General

13.3.1

Identification

13.3.2

Pre-Use Operational

13.3.3

Operational

13.4 13.4.1 14.0

......................................................

of Mobile Aerial Platforms

Checks..........................................................

Use. .................................................

Hand trucks ................................................ General

....................6

................................................. .........

................................

67 68

............................................70

Requirements..................................................................

Crane Operation......................................................................

Page 7 of 247

7 . 67

.........

70

................7

1

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

14.1

Introduction

14.2

Regulations and D

14.3

Lifting Team............................................................................................71

14.4

Crane Operator

14.4.1

.................................................... ocuments for safe

........................................71

Offshore Crane Oper

ations ........................71

...................................................

Crane Operator’s

Responsibilities

....................................71

..............................................

Rigger/Slinger

14.6

Banksman...............................................................................................72

14.7 14.8

Banksman/Slinger Activities.......................................................................72 Load Charts ................................................ ............................................75

14.9

Protocol for the

use of two-way radio

14.10

Two-way Radio

Communications -

14.10.1 14.11

................................................

.............

14.5

Banksman -

communications General Information

Radio Comm unication

.....................................76 ....................................76

...........................................................

Pre-Use Crane Inspection.............................................................. Pre-requisites.......................

14.11.2

Crane Access.......................................................................................

14.11.3

Housekeeping

14.11.4

Safety Equipment.................................................................................

14.11.5

Crane Pre-start

Checks ......................................................

14.11.6

Pre-use checks

for cranes not in

14.11.7

Crane R efuelling..................................................................

14.11.8

Crane Start-up

.......................................................

..............................................

........................................

use for an extended per

.............................................

.................... iod of time

................

.................

Function Test

Rated Capacity In

14.12.4

Emergency Load Release

14.12.5

Emergency

14.12.6

System Checks Whilst Crane is Running ....................................................

14.14.1 14.14.2 14.14.3 14.15

..... 80

dicators RCI (Au

tomatic Safe

Load Indicators

- ASLI) ............

System.................................................. .....................................................

on the Platform

Platform

....................

Deck........................................

Lifts .........................................

82

.............

82

Lifts ................................................ Lifts ......................................................

82

.....................83

........................................

83

........................................

83

Deck Work ..................................................

Non-routine

81

. 82

............................

Cargo handling - supply vessel work........................................................... Routine

81

.............

................................................

Lifts ................................................

14.15.2 14.15.3

Limit Switc h Cut-ou ts ......................................................

...........................................

14.15.1

14.16

80

Stop Buttons

Non-routine

0

Controls...................................................................

Routine Crane Operations.............................................................

Routine

79 80

.....................8

14.12.3

Load Handling

78 79

........................................

14.12.2

14.14

78 . 78

Crane Function Tests............................................................

Signalling

77 78

Function Test Crane

14.13.1

77

.........

14.12.1

14.13

. 77 .............

14.11.1

14.12

72

........................................72

83 . 85

........................................

85

............................

85

V e s s e l C a r g o H a ndl i ng O pe r a t i o ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5 Transport of

scaffolding Materials

and Board s ..............................................

Page 8 of 247

. 86

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

14.17

General Ope

rating Instru

14.17.1

Stabilise

14.17.2

Trial Lifting

15.0

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

ctions ......................................................

the Lift ............................................... .............................................

Sub-sea Lifting

and hoisting

operations

.............

Competence

Categorisation of Lifts......................................................................

15.3

Lift Planning

15.4 15.5

Management of Change................................................................ Sub-sea lifting rules & sub-sea c larifications ................................................

15.6

Load Handling.....................................................................

15.7

Competence of

15.8

Load Charts ................................................

15.9

Crane Maintenance

15.10

Rope Maintenance.......................................................................

15.11

Crane Inspection..................................................................

15.12

Rope Inspection

15.13

Crane/Rope Records............................................................

16.1

................................................

............................................89

...............................................

.........

0

............................................90 ............................90

...................................................

.............

91

....................9

1

....................................91 .....................9

..............................................

2

............................93

Documents..............................................................................................93 Load Charts ................................................

Sitting of Cranes.................................................................................

16.4

Preparation

16.5

Lift Plans................................................................................................96

16.6

Environmental

16.7

General Ope

............................................93

................................................

Conditions rating Instru

Multiple Crane

..... 94

............................................95

..............................................

............................96

ctions ..................................................

Lifts ..............................................

Safety Measures for

17.2

Calculated Share of the Load......................................................................98

17.3

Principles for Multiple Crane Lifting.............................................................98

17.4

Mass of the Load .....................................................

17.5

Position of the

17.6

Mass of the Lifting

17.7

Safe Working Capacity

17.8

Synchronisation Precautions when

Multiple Crane Lifts

.................

Centre of Gravity

..............................................

of the Lifting Gear

of Crane Motions

.........

.................

Lattice

18.2

Hydraulic

...............................................

..................................................

Boom Cranes .............................................

18.3

Precautions with Pick-and

Boom Cranes ................................................. -Carry Cranes................................

99

............................99 ..... 99 .............

Using Mobile Cranes.......................................................

18.1

98

................................99

................................................

Gear ................................................

97

....................................98

17.1

19.0

89 . 89

............................90

16.3

18.0

.............

....................9

...............................................

16.2

17.0

89

............................................89

......................................................

Mobile Crane Operations

88

........................................................89

15.2

16

88

............................................

15.1

Personnel

87

....................................

.................................. .......................... ......................

99 100 100 100 100

V e hi cl e -L o adi ng C r a ne s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 1

Page 9 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

19.1

General

19.2

Crane and V ehicle Suitability

19.3

Rated Capac ity Limiters................................................................

19.4

Operational Issues for Vehic

20.0

use ................................................

..........................................

.................................................

Risks .............................................

20.2

Make-up of Lines .................................................

21.1

In Use................................ Sling Wire Diameters and Multi-leg

23.0

Pre & Post-Use Introduction

23.2

Lifting Appliances

23.3 24.0 24.1

Identification

Portable Lifting

Equipment

Standards

105

Lifting Appliances and Lifting

Tackle ...... 107

..................................

.........................................

Appliances and

Lifting Tackle

.......................

................................................

..............................

Certification/Change

24.4

Equipment

24.5

Contents Register and Other Doc

24.6

Rigging

24.7

Colour Codin

24.8

Cleaning

24.9

Maintenance

..............................................

......................

24.10

Damaged Lifting E quipment ...............................................

......................

24.11

Retirement of

24.12 24.12.1 24.12.2 24.13 25.0

108

......................

..................................................

..................................................

.........................................

108

...........

umentation.....................................

108

...........

109

..........................

g....................................................................

109

..................

109

..................................

109 110 110

Lifting Equipment................................................................ Own Lifting Equipment On

Marking/Tracking

Equipment Reg

ister and

Pre-Use Inspection

Other Doc umentation

- Basic Requirements

Equipment

25.2

Identification

Identification

25.3

Colour Codin

25.4

Documentation Ac

110

SMEP Platforms/Worksites....

............................................

110

...................

...........................................

use for an extended

111

period of time

Markings .................................................

... 112 ...........

Number/Mark.................................................................... g System................................................................. companying Lifting

110 110

....................................................

for lifting appliances not in

25.1

26.0

out ..................................................

Contractors Using Their

Pre-use checks

108

..................................................

Marking and Tracking

Equipment

107 108

24.3

and Inspection

107

...............................

Storage.............................................

of Equipment

107

...........

24.2

Store Control

103 105

... 106

Tackle ..............................................

and Certification

Control Of

................... .......

......................................

....................................................... and Lifting

103 103

...................................................

Checks and Safe Use of

23.1

103

..................................

Slings ..............................................

Pallets ...........................................

101

......................................................

............................................... Master links ................................................

22.0

101

..........

..........................................

20.1

20.3 21.0

101

...........

le-Loading Cranes...................................

Use of Tag Lines ..........................................

101

..................

Equipment..........................................

112 112

...........

112 113

W i r e R ope a nd W i r e R ope S l i ng s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4

26.1

W i r e Ro pe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4

26.2

Types of Lay ..............................................

Page 10 of 247

..........................................

114

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

26.3

W i r e Ro pe Sl i ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 5

26.4

Sling Identification................................................................................

26.5

Pre-use .........................................

26.6 27.0

Safe Use ............................................

..................................................

Rejection..................................................................................

27.2

Care and maintenance

28.1

... 117 117

W i r e C l a m p ( AS B RO ) P r e -U s e Ins pe ct i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 2

27.1

27.3 28.0

115

...................................................

.........................................

........... ..................................

122 122

After Use ............................................................................................ 122 Chain Slings and Fittings...................................................................... ... 123 Barrel Slings ..............................................

...........................................

123

28.2

Pre-use .........................................

28.3

Safe Use ...................................................

28.4

After Use ............................................................................................ 125

28.5 29.0

................................................... ..........................................

Barrel Lifters .................................................. Man-Made Fibre (Webbing

... 124 124

......................................

) Slings..............................................

125

...............

127

29.1

W e bbi ng ( R ou nd and F l at ) S l i ng W L L C ol o ur C o di ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 8

29.2

Pre-use .........................................

29.3

Safe Use ...................................................

29.4

Prohibited

29.5 29.6 30.0 30.1

Special

31.3 32.0

130

Hooks....................................................................................... Pre-use .........................................

Safe Use ............................................

31.2

129

Applications..............................................................................

Scissor Hook

31.1

129

......................................

After Use ............................................................................................. 130

30.3

31.0

... 129

..........................................

Lifts ...............................................

30.2

30.4

...................................................

...........

...................................................

Inspection...........................................................................

132 ... 133 134

..................................................

134

After Use ............................................................................................ 135 Shackles

............................................

Pre-use Inspection

..................................................

...................................................

Safe Use ............................................

..............................

..................................................

136 136 137

After Use ............................................................................................ 139 Eyebolts ............................................

................................................

...................................................

Eyebolt with Link.......

32.2

Collar Eyebolt .............................................

32.3

Pre-use Inspection

32.4

Safe Use ............................................

32.5

After Use ............................................................................................. 144

32.6

Swivel H oist Rings............................................................

............................................

32.7

Pre-use .........................................

32.8

Safe Use ...................................................

..........................

... 140

32.1

140

......................................

141

..................................................

......................

...................................................

Page 11 of 247

140

..........................................

..........................................

142

144 ... 145 145

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

32.9 33.0 33.1

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

After Use ............................................................................................ 145 Beam Clamps .............................................. Universal

Superclamps

..........................................

..................................................

33.2

Pre-use Inspection

33.3

Beam Clamp Safe Use ..................................................

33.4 34.0

...................................................

..........................

146 146

..............................

147

..........................

147

After Use ............................................................................................. 148 Beam Trolleys......................................................................

..................

149

34.1 34.2

Push Type Trolleys...................................................................... ........... Gear Type Trolleys .............................................. ..................................

149 149

34.3

Beam Trolley

149

34.4

A nt i - t i l t D e v i ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 0

34.5

Pre-use Inspection

34.6

Safe Use ...................................................

34.7

After Use ............................................................................................ 151

35.0

Installation

..............................................

...................................................

Pre-use .........................................

35.2

Horizontal

35.3

Universal

35.4

36.1 36.2 37.0

(Vertical)

Safe Use of Plate Clamps ...................................................... .................................................

Pre-use ..........................................

Pre-use ......................................... Safe Use ...................................................

..................

155

..................

157 ... 157

..........................................

Lifting Nipples

and Lifting

...................................................

158

Pre-Use.....................................................................

38.2

Safe Use ................................................... Runway Beam Beam Identity

39.2

Uncertified

39.3

Pre-use Inspection

39.4

Safe Use ................................................... Lifting

............... ..........................

..........................................

s.............................................................

39.1

............................................. Lifting

... 161

..........................................

Caps .................................................

38.1

40.0

153 154

W e dge a nd So ck e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 0

37.2

39.0

...............

...................................................

Safe Use ...................................................

151

... 153

......................

Plate Clamps .............................................

Rigging Sc rews / Turnbuckles

150

... 152

...................................................

Plate Clamps ...................................................

37.1

38.0

.............................. ..........................................

Plate Clamps......................................................................................

35.1

36.0

..........................

.......................... ..........................................

Beams ...................................................... ...................................................

.................. ..............................

..........................................

Points......................................................................................

40.1

Padeyes ................................................

40.2

Bolt-on P ad Eyes................................................................

40.3

Pre-use Inspection

40.4

Safe Use ...................................................

40.5

Other Types of Lifting

Page 12 of 247

................... ..............................

..........................................

Points .............................................

163 163 164 164 165 165 166 ... 167

..............................................

...................................................

162 163

......................

167 168 168 168 169

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

40.6

AND HOISTING

MANUAL

REV.1.0

A ddi t i o nal L i f t i ng P o i nt s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 9

41.0

Spreader

42.0

Manually-Operated

Beams and Lifting

Frames ................................................

Hoists .............................................

42.1

Ratchet Lever Blocks (Pull Lifts or Chain Lever H

42.2

Pre-use .........................................

42.3

Safe Use ...................................................

42.4

SMEP.EP200802258279

........... ..........................

oist).....................................

171 172 172

...................................................

... 173

..........................................

174

After Use ............................................................................................. 177

42.5 42.6

Ratchet Lever Blocks in an Offshore Sub-Sea Environment.............................. Hand-Operated Chain Blocks........................................................

42.7

Chain Block Usage Terminology

42.8

V a r i o us T y pes o f C ha i n B l o c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 9

42.9

Chain Block

42.10

Pre-use .........................................

42.11

Safe Use ...................................................

42.12

After Use ............................................................................................ 183

42.13 43.0

............................................

43.2

Electrically P

43.3

Pre-use .........................................

43.4

Pulling (Tirfor)

Machines

181

................... ...........

...................................................

185 185 185 ... 186

..........................................

...............................................

...........

Tirfor Use

44.2

Pre-use .........................................

...................................................

44.3

Inserting the

Tirfor Mach ine ..............................

44.4

Safe Use ...................................................

44.5

After Use ............................................................................................ 191

Maxiflex Load

.........................................

Rope into the

...................

187 188

44.1

45.0

- Safety Considerations

179

184

..................................

Hoists ..................................................

Safe Use ................................................... Lifting and

179

... 180

Environment.............................

Chain Hoists ....................................................... owered Chain

177 178

..........................................

in an Offshore Sub-Sea

Pneumatic

...................

...................................................

Powered Chain Hoists ...........................................

43.1

44.0

...................

Safety Considerations.........................................

Manual Chain Blocks

...........

..........................................

Snatch Blocks ..............................................

..........................................

188 ... 188 190 190

192

45.1

W i r e r o pe P ul l e y B l o ck s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 2

45.2

Pre-use .........................................

45.3

Safe Use ...................................................

45.4

After Use ............................................................................................ 194

46.0 46.1 46.2 46.2.1 46.3 46.3 46.3.1

................................................... ..........................................

... 192 193

W i nche s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 5 Man-riding Hand-Operated

Winches .................................................... Winches

...............................................

..........................

196

..........................

197

Pre-use.......................................................................... Safe Use ................................................... Electric or Air

................... ..........................................

Driven Winches..................................................................

Pre-use..........................................................................

Page 13 of 247

197 198 198

...................

198

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

46.4 47.0

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Safe Use ................................................... Hydraulic Jacks, Rams and P

..........................................

umps....................................

199

..........................

200

47.1

Pre-use .........................................

47.2

Ratchet

47.3

Hydraulic

47.4

Safe Use ...................................................

47.5

After Use ............................................................................................ 202

48.0 48.1

...................................................

Jacks ............................................. Jacks ..............................................

Pre Use .................................................

48.3

Safe Use ...................................................

48.3.1

201

..........................................

202

203 ... 203

..............................................

204

..........................................

Do Not: ..............................................

205

..............................................

206

V e hi cl e L oa di ng C r a ne s ( e . g . H i a b C r a ne ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 7

49.1

Pre Use .................................................

49.2

Safe Use ...................................................

50.0

201

......................................

Overheard Cranes.................................................................................. Hoisting and Travelling Units................................................................

48.2

49.0

... 201

..........................................

Flexible Intermediate

Bulk Containe

..............................................

207

..........................................

207

rs (FIBC) ................................................

Lifting

50.2

Pre-Use.....................................................................

50.3

Repair of FIBCs ..............................................

......................................

208

50.4

How to u se FIBC s ............................................

......................................

208

50.5

Lifting

FIBCs ......................................................

..................................

209

50.6

Lifting

with Cranes ..............................................

..................................

210

50.7 51.0 51.1 51.2 52.0 52.1

of filled FIBCs ...............................................

208

50.1

Carrying

With Fork

..............................

208

..........................

Lift Truck s ......................................................

Containers......................................................

208

...........

210

......................................

212

W i r e r o pe s l i ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 2 ISO Containers

...................................................

Pennants/Stingers

..................................

................................................

Pennant Assembly

..................................................

213

..................................

214

...............................

214

A ppe ndi x 1

Crane B anksman Hand Signals............................................................

A ppe ndi x 2

Flow Cha rt Lifting

A ppe ndi x 3

Mobile Crane

A ppe ndi x 4

A ppl i a nce L i f t P l a nni ng She e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 3

A ppe ndi x 5

Carrier Transfer

A ppe ndi x 6

C a r r i e r T r a ns f e r P a s s e ng e r C he ck l i s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 6

and Hoisting

Lift Planning

Checklist

Operations

215

...........................................

219

Sheet ......................................................

.......................................................

... 221

...........

225

A ppe ndi x 7

P e r s o nne l T r ans f e r R e que s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 7

A ppe ndi x 8

Installation Of

A ppe ndi x 9

Shackle – S plit Pin Sizes...........................................

Wire Rope

A ppe ndi x 10

Overload P rotection

A ppe ndi x 11

Glossary

Double Saddle

and Anti-Two-B

Grips ......................................

lock R equirements

of Terms .............................................

Page 14 of 247

......................... ............................ ..............................

228 230 231 232

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

1.0

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

PREFACE.

W he n i t e m s ar e l i f t e d i t i s o f t e n t he ca s e t ha t t he f i r s t a v ai l abl e pi e ce o f l i f t i ng e qu i pm e nt i s used. Conveniently available lifting appliances and lifting tackle are randomly requisitioned and the lift undertaken and often with disastrous consequences. The “can do”

attitude often

contributes to the eventual accident. A l t ho u gh t he a bo v e ba d pr a ct i ce ca nno t be i de nt i f i e d t o a s pe ci f i c a r e a o f t he o i l a nd g a s exploration and production industry, the dangers of the “can do” attitude must be understood if accidents are to be avoided. No job is so important that

cannot be carried out safely.

The author and review team members would like readers to note that, whilst every practical attempt was made to ensure the accuracy and scope of the content of t his document, due to the size of the task and the given ti mescale, there may be some unintentional errors or omissions. Comments (recommendations, additions or deletions) and any pertinent data that may be of

use

in improving this document are encouraged and should be addressed to the author for consideration for inclusion in the next revision. Users are cautioned that adherence to this Manual alone does not exclude the use of competent engineering judgment.

1.1

Possible Reasons For Accidents

Possible contributory reasons for accidents occurring during lifting operations

are briefly listed

below.

1.1.1

Contributory

Factors

•

Inadequate planning of the lifting operation.

•

Inadequate pre-operation risk assessment.

•

Inadequate control of operations

•

Inadequate operator training standards.

•

Inadequate continuous assessment systems.

•

A cce pt a nce o f t he “ c an do ” c ul t ur e .

1.1.2

Operator Error

Operator errors such as “overloading”, incorrect selection

of equipment, incorrect attachment

of equipment, inability to recognize faulty equipment etc. can often be attributed to: •

Incorrect level of “Competency”.

•

Inadequate training.

•

Inadequate job information

•

Not recognizing the hazards involved.

1.1.3

Equipment

Failure

Equipment failure is often due to: •

Inadequate storage facilities.

Page 15 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

•

Inadequate routine maintenance management.

•

Lack of examination and certification

•

Lack of written routine maintenance instructions.

•

Misuse.

REV.1.0

In order to avoid lifting incidents, the introduction and implementation of a “Safe

System of

W o r k ” i s e ss ent i al . Before any lifting operation takes place a briefing (toolbox talk) involved in order that the requirements of the lift are fully

1.1.4

must be given to all personnel understood.

Safe System of Work

A s a f e s ys t e m o f w o r k i s a s t e p-by -s t e p de s cr i pt i o n o f a ny t a s k or pr o ce s s t ha t t ak e s i nt o account the hazards likely to be encountered. The following summarises the requirements of a safe system of

•

Define the task.

•

A s s e s s t he r i s k s .

•

Describe safe methods by writing /checking of lifting plan.

•

Measure and monitor its effectiveness.

work:

The safe system of work procedures must also address the effective is

olation of supplies and

systems from the work area and stipulate what effective barriers must be in pl

ace to distance

personnel working in the area from any hazard or danger. It is essential that t

he safe system of

w o r k l i s t s a l l s af e t y pr e c a ut i o ns t hat m us t be t ak e n a t ea ch s t a g e o f t he w o r k .

1.1.5

Requirements

of a Safe System of Work.

The following gives a brief summary of the subjects that

must be considered before any lifting

operation is started.

Pre assessment:

A s s e s s t he ha z a r ds a nd a s s o ci a te d r i sk s . A s s e s s t he co m pl e x i t y o f t he wo r k .

J o b P l a n n i n g :Plan the work with respect to all personnel that

are directly or indirectly

involved. For example: •

Removal of an item of equipment from an enclosed bay on a platform may involve moving other personnel from the work area, closing access routes and/or removal of structures to establish a removal route.

•

How inherently dangerous is the task? What could go wrong? What could happen if the task is incorrectly performed?

•

Break down each individual’s task into steps or component activities and examine each step to see what could go wrong.

Equipment provision:

Check availability of lifting appliances, lifting tackle and

required for every phase of the operation. Lifting appliances and tackle must be “certified” and

Page 16 of 247

quantities

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

comply fully with SMEP requirements. All equipment used during the lifting operation must undergo pre-use, pre-start and function checks. W o r k A re a :W o r k ar e a s w i l l ha v e di f f e r i ng co ns t r a i nt s ; t he a r e a m a y ha v e r e s t r i c t e d m a chi ne r y

space, or one where the lift is being carried out on an open

deck. Each must be considered on

it’s own individual merits. Environment:

Environmental considerations shall include external weather conditions and

internal constraints such as confined spaces e.g. Ensure that the area is gas free before entry and arrange for continuous monitoring during work period. Personnel: Numbers must be adequate to safely carry out the task. Anticipate the possible need for assistance, shift changes, back up etc. Is additional Personnel Protective Equipment (PPE)

required? Communication:

Establish a clear and effective system of communication between all personnel

involved in the lifting operation. Person In Charge (PIC):

Organise the person in charge for the task and personnel involved.

Emergencies: Anticipate emergency requirements. Handover Log:

Initiate a shift change handover log, which must be maintained so that it

correctly informs the incoming shift of the current status of the lift

ing operation.

Report all incidents that occurred during the operation and provide a meaningful summary using the Fountain reporting system. Reporting System:

Page 17 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

2.0

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Purpose

The purpose of this document is to describe how lift

ing equipment and activities, operated

w i t hi n S M E P o ns ho r e and o f f s ho r e fa c i l i t i e s a nd a t a ny w o r k s i t e w her e S M E P ha s a pr ev ai l i ng influence, are identified and that hazards associated with these activities identified, assessed and kept as low as

2.1

are correctly

reasonably possible (ALARP).

Scope

This standard applies to all SMEP and Contractors at all

locations where SMEP has the

prevailing influence. It covers lifting operations in connection with all the li

fting equipment listed in Table 1 below.

Lifting Equipment

L i f t in A g p p li a n c e

Lifting Tackle

L i f t e dE qu i p m en t

Cranes (Including): Offshore pedestal Mobile cranes A-Frames and derricks – not drilling (onshore and on barges) Tower cranes Overhead/gantry cranes

Wire rope slings Chain and chain slings Man made fibre slings Shackles Plate clamps Eye bolts and swivel Rings

Offshore containers Skips Skids Spreader beams Drum cages Gas cylinder racks Frames

Lorry loading cranes (HIAB’s) Runway beams/monorails Jacks Mobile Aerial Platforms Hoists • Manual lever • Tirfor/comealong •Powered overhead •Chain hoist •Chain block Padeyes (fixed structural) Winches (incl.Man-riding) Forklift trucks Beam clamps Beam trolley Sheave blocks

Cargo Basketsnetting Pipe racks FIBC’’s (Big Bags) Pallets

Table 1.

Page 18 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

3.0

Certification

3.1

Introduction

SMEP.EP200802258279

MANUAL

REV.1.0

A l l l i f t i ng e qui pm e nt us e d o n S M E P o ns ho r e o r o f f s ho r e f a ci l i t i e s by S M E P pe r s o nne l , contractors or sub-contractors shall be accompanied by a

current valid certificate of

examination. NOTE.

RD

CERTIFICATES OF EXAMINATION MUST BE ISSUED BY A SMEP RECOGNISED 3 PARTY LIFTING CERTIFICATION AUTHORITY.

3.2

Certification

3.2.1

Inspection

With New Lifting Equipment Certificate

A de c l a r at i on by t he m a nuf a ct ur e r t ha t t he pr o duc t s s u ppl i e d m e e t t he r e qui r e m ent s o f t he order and which supplies specific test results. The Inspection certificate shall meet

the

requirements of ISO 10474 type 3.1B or BS EN 10204:2004. Inspection Certificates for any item of lifting equipment shall safe place and be readily accessible for as long as

be kept by the owner/user in a the equipment is in use. The Inspection

Certificate shall accompany lifting equipment being transferred for use in a different location.

3.2.2

Operating

and Maintenance

Instructions

It is a requirement that written Operating and Maintenance Instructions must accompany all new equipment. These instructions (or photocopies) must be kept in a pl

ace of safety, with the

equipment, and be readily available to the end user. They are normally stored at the location where the l

ifting equipment is being used. However,

w he r e t hi s i s no t po s s i bl e e . g . due t o s pa ce co ns t r a i nt s , t he y m ay be s t or e d e l s e whe r e pr ov i de d that they are readily accessible.

3.3

Certification

of Existing Lifting Equipment

A l l l i f t i ng e qu i pm e nt o n S M E P f a ci l i t i e s , a nd t ho s e o wne d by co nt r a ct o r s o r s ub- co nt a ct o r s us e d on SMEP onshore or offshore facilitates or where SMEP has the prevailing influence, shall accompanied by a current valid certificate of

examination issued from a SMEP

party certification company.

3.4

Retention

3.4.1

Inspection

Period for Certificates

and Reports.

Certificates

Inspection Certificates are valid for the lifespan of the l

Page 19 of 247

ifting equipment.

be recognised third

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.4.2

AND HOISTING

Thorough Examination

SMEP.EP200802258279

MANUAL

REV.1.0

Certificates

The owner of lifting equipment is responsible for ensuring that all

lifting equipment is

examined and certified in accordance with IMP 0.03 Lifting Equipment Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032). Thorough Examination Certificates/ Reports are a record of the physical condition of lifting equipment at that moment in time and any testing

that was carried out. When statutory testing

is carried out and the results recorded, a date for retesting will

be specified and such

Certificates and Reports are considered to have finite validity.

The retention period for certificates and reports are listed in EPA Document Management Code of Practice EPA 20040901 0001.

Page 20 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

4.0

Maintenance of Lifting Equipment

4.1

Introduction

SMEP.EP200802258279

REV.1.0

A l l l i f t i ng e qu i pm e nt o n S M E P f a ci l i t i e s , a nd t ho s e o w ne d by co nt r act o r s o r s ub- co nt a ct o r s us e d on SMEP onshore or offshore facilitates or where SMEP has the prevailing influence shall

have

a preventive maintenance routine and shall be maintained by personnel qualified to undertake this work.

A l l SM E P i t e m s o f l i f t i ng e qui pm e nt , wi t h t he e x ce pt i o n o f l o o s e l i f ti ng t a ck l e , s ha l l be registered in SAP. The maintenance, examination and overhaul intervals shall be as per A ppe ndi x 1 o f I M P 0 . 0 3 L i f t i ng E qu i pm e nt I ns pe ct i o n a nd M a i nt e na nce P hi l o so phy (SMEP.EP72.ST.0032) or the manufactures maintenance instructions. Contractors shall maintain a register of all their owned lifting equipment.

A t t e nt i o n i s dr a w n t o S he l l ’ s g l o bal s t a nda r d o n l i f t i ng a nd ho i s t i ng E P 2 0 0 5- 0 2 6 4 - ST ( s e ct i o n 4.10 page 13) The maintenance history of all items of

lifting equipment shall be fully captured in SAP.

Contractors shall maintain maintenance history of all their owned lifting equipment.

Page 21 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

5.0

Marking of Lifting Equipment

5.1

Requirements

It is the requirement of SMEP to have all

lifting equipment clearly marked to indicate their

w o r k i ng l o a d l i m i t o r s a f e w o r k i ng l o a d. 1.

Where the working load limit or safe working load of the equipment

depends

on its

configuration, the equipment shall be clearly marked to indicate its working load limit or safe working load for 2.

Lifting

each configuration.

tackle shall be marked in such a way that it is possible

to identify

the

characteristics necessary for their safe use. 3.

Lifting

equipment,

which is designed

for lifting

persons,

is appropriately

and clearly

marked to this effect.

5.2

Working Load Limit (WLL)/ Safe Working Load (SWL)

5.2.1

Safe Working Load (SWL) Mark

The SWL marking indicates the maximum load that the equipment may safely lift

as certified by

the competent person. W he r e v e r po s s i bl e , t he act ua l v a l u e o f t he SW L m u s t be m a r k e d ( s t am pe d) o n t he e qui pm e nt i n such a way that it cannot be easily removed. Where this is

not practicable a system may be

used to provide the user with the SWL e.g. attaching some l

abel or tag (as happens with man-

made fibre slings. The Safe Working Load (SWL) is a method of s

tating the maximum load or mass that an item

of

lifting equipment may raise, lower, or suspend.

5.2.2

Working Load Limit (WLL) Mark

The Working Load Limit (WLL) is an

internationally used term (meaning the same as SWL). The

W L L m a r k i ng i ndi ca t e s t he m a x i m um l o a d t ha t t he e qui pm e nt i s de s i gne d t o s af e l y l i f t ; t he manufacturer normally marks it on the equipment. Sometimes it is referred to as the equipment’s “rated capacity”.

5.2.3

Variable WLL or SWL

W he r e l i f t i ng m a chi ne r y ha s a W L L o r SW L w hi ch v ar i e s w i t h i t ’ s ope r at i ng r a di us o r i s dependant upon how it is configured, it must be either clearly marked or have adequate information to indicate to the user it’s

WLL or SWL at any particular configuration. These

markings can be in the form of an indicator, plate or chart, which is normally visible/available to the operator during lifting operations. W he r e t he r e i s a s i gni f i ca nt ha z a r d a r i s i ng f r o m t he u s e o f t he m a c hi ne r y i t m us t ha v e appropriate equipment or devices such as rated capacity indicators and rated capacity limiters. Rated Capacity Indicators (RCI) were previously known as Automatic Safe Load Indicators (ASLI’s) or Safe Load Indicators (SLI’s) or moment load indicators.

Page 22 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

5.2.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

De-rating

If it is not possible

to provide a value for the SWL for all configurations, the capacity of the

equipment must be reduced (de-rated) to allow for all configurations for a factor of safety. W he n ne c e s s a r y , t hi s f o r m o f de -r a t i ng m us t o nl y be c a r r i e d o ut by a co m pe t e nt pe r s o n i n consultation with the equipment manufacturer and reviewed by the Lifting Technical Authority.

5.2.5

Lifting Equipment

assembly

W he r e a num be r o f pi e c e s o f l i f t i ng t a ck l e a r e a s s e m bl e d t o f o r m o ne l i f t i ng as s e m bl y , w hi c h i s not dismantled after use, the assembly must be permanently marked to indicate it’s

assembled

W o r k i ng L o a d L i m i t ( W L L ) . i . e . M ul t i -l e g s l i ng s a r e m ar k e d w i t h i t s W L L a nd t he a ng l e ( f r o m t he v e r t i c al ) a t whi ch t he W L L a ppl i e s , e . g . S W L x T o nne 0 ° to 45

5.2.6

Lifting Accessory

°

from the vertical.

Configurations

If the configuration of an accessory can effect the WLL or SWL, e.g. multi-legged sling, it must be clearly and permanently marked to provide the user with information on the SWL for each configuration e.g. 6.9 tonne @ 0 to 45 degrees from the vertical.

5.2.7

Accessories-

Other Factors

If a lifting accessory, such as a plate clamp, can be adversely affected by other factors, must be clearly marked with the plate thickness range of plates over which it

this can be safely

used.

5.2.8

Lifting Equipment

for Lifting Persons

Lifting equipment, which is designed for lifting persons, must be marked that it is for lifting persons. In

clearly and permanently

addition, the carrier (e.g. a suspended personnel

basket) must clearly display the maximum number of persons to be carried. The SWL must also be clearly and permanently marked on the carrier. For details of equipment used for personnel lifting see

Section 9

.

Lifting equipment, which may be inadvertently used for lifting people, but was not de that purpose, shall be clearly and permanently marked that it is not t

signed for o be used for lifting

people.

5.2.9

Gangways

A l l pl a t f o r m g a ngw a y l i f t i ng / r i ggi n g e qui pm e nt s ha l l be cl e a r l y t a gg e d i ndi ca t i ng t he s a f e w o r k i ng l o a d m a x i m um r i g gi ng an gl e f r o m t he v e r t i ca l w he n i n s e r v i ce .

5.2.10

Equipment

Identity Marking

A l l i t e m s o f l i f t i ng e qui pm e nt s ha l l hav e a pe r m a ne nt uni que i de nt i fi ca t i o n nu m be r m a r k e d o n, or attached to it, through which it can be identified throughout its lifespan.

Page 23 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

6.0

Lifting Equipment Colour Codes

6.1

Lifting Equipment

SMEP.EP200802258279

REV.1.0

Colour Coding System

A l l l i f ti ng t a c k l e o w ne d by S M E P o r us e d o n S M E P of f s ho r e o r o ns ho r e f ac i l i t i e s m u s t u nde r g o a thorough inspection every 6 months. The colour coding system used by SMEP, is detailed in IMP0.03 Lifting Equipment )SMEP.EP72.ST.0032), is to indicate to end users that the lifting tackle has passed the 6 monthly thorough inspection and is s uitable for use. The colour code is v al i d f o r a s e t pe r i o d o f 6 m o nt hs a nd o nl y l i f t i ng t a c k l e di s pl ay i ng t hi s co l o ur co de m ay be used. The colour code, which is currently valid, shall be displayed at all SMEP locations where li and hoisting activities are carried out.

Page 24 of 247

fting

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

7.0

Training of Personnel

7.1

Training Responsibilities

REV.1.0

A l l SM E P a nd C o nt r a ct o r pe r s o nne l e ng a ge d i n l i f t i ng a nd hoi s t i ng o pe r a t i o ns s ha l l m e e t t he Competence Standards set out in Appendix 1 of Lifting Equipment Management System EP200803208668. Whe re def icienci es ar e found they shall be add ressed by tra ining. The t raining must provide levels of competence that will eliminate incorrect operations/activities and minimize the potential for human error that might otherwise contribute to an incident.

7.2

Training

Personnel who must be adequately trained are listed in Appendix 1 of Li

fting Equipment

Managem ent S ystem EP200803208668. The t rainin g sha ll b e und ertaken

at a SMEP a pproved

training provider.

7.2.1

Additional

Training

A ddi t i o nal t r a i ni ng w i l l be ne ce s s a r y w he n: •

The risks to which personnel are exposed to change due to a

•

New equipment is introduced.

•

The system of work changes.

7.2.2

Training for New and Inexperienced

change in work tasks.

Personnel

Training and supervision of new personnel is particularly important because of their unfamiliarity with the working environment. Safety induction and familiarisation training shall be carried out.

7.2.3

Personnel

Under Training

Personnel under training must only undertake tasks appropriate to their assessed level of competence.

7.2.4

Qualification

Updates

Some qualifications are valid for a set period of time after which they qualification is required. A system must be in place to keep track of this re-qualification.

Page 25 of 247

expire and reand ensure a timely

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

8.0

Planning, Definitions and Execution of Lifts

8.1

Purpose

The key to safe lifting operations

in SMEP is having competent personnel using the correct

equipment in a planned safe manner. This section outlines the

issues relating to the selection of

the correct people, i.e. crane operator, banksman, rigger etc. for the task. It describes operational practices to be used by these people as part of a planned safe and effective crane and rigging programme. A t t e nt i o n i s dr a wn t o t he r e l ev ant s e c t i o ns o f t he S he l l gl o bal s t a ndar d o n l i f t i ng a nd hoi s t i ng EP2005-0264-SP-01 (Section 4.2.2) and EP2005-0264-GL-01.

8.2

Scope

This section applies for all lift

8.3

s using lifting appliances and accessories.

Responsibilities

The responsibilities of SMEP’s activity managers, supervisors, CSR’s OIM’s etc. and personnel involved in lifting operations can be found in Section 2.3 of

Lifting Equipment Management

Sy st em , EP200803208668.

8.4

Correct Use

The equipment shall be used only for the

specific purpose for which it was designed and not be

adapted for any other purpose without the approval of the Lifting Technical Authority.

8.5

Safety Margin

A l l l i f t i ng e qu i pm e nt and appl i a nc e s u s e d i n t he l i f ti ng pr o c e s s s ha l l be r at e d at 3 0 % o r m o r e above the maximum load to be lifted.

8.6

Controlling

Access to the Lift Area

A cc es s t o w or k a r e as a nd t o t he l i f t i ng e qui pm e nt s ha l l be pr o pe r l y co nt r o l l e d. T hi s m ay include security measures and physical barriers. No person shall be allowed under a suspended load unless: •

There is clear justification and no suitable alternative was identified during planning

•

A n i nde pe nde nt s e c ond ba r r i e r i s i n pl ace .

8.7

Risk Assessment

8.7.1

Lift Plan/JSA

Every lifting operation must have a lift plan and JSA

Page 26 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

Every lifting operation shall be preceded by a Lift

REV.1.0

Plan and JSA to identify hazards, and ensure

that safety barriers are in place to reduce the risk to As (ALARP). The Risk Assessment shall

SMEP.EP200802258279

Low As Reasonably Practicable

address, but is not limited to the fol

lowing:

•

Classification of the lift.

•

W e i ght s i z e , s hape a nd ce nt r e o f g r a v i t y

•

Av ai l a bi l i t y o f appr ov ed l i ft i ng po i nt s .

•

Methods of slinging, attaching and detaching the load.

•

Overturning, load integrity and the need for tag lines.

•

Suitability and condition of the lifting equipment to be used.

•

Initial and final load position, and how it

•

Lifting over live equipment.

•

Number and duration of lifts.

•

Conflicting tasks in the lifting area.

•

Environmental conditions, including weather and permissible limits.

•

Ground conditions and the expected

•

Lighting in the pick-up and lay down areas.

•

Proximity hazards, obstructions, path of load.

•

W or k i ng unde r s us pe nde d l o a ds .

•

A cce s s and e m e r ge ncy e s cape r o ut e s o f t he l i f t i ng e qui pm e nt o pe r at o r a nd l o a d

will get there.

ground loadings.

handlers. •

Experience, competence and training of personnel

•

Number of people required for the task.

•

Step by step instructions.

•

Pre-use Inspection of equipment by the operator.

•

V i s i bi l i t y of the l o a d by t he o pe r a t o r a nd pe r s o n g ui di ng t he l oa d.

•

Method of communication between all personnel involvedin the operation and the , chain of command is clear.

•

Recovery and contingency plans.

Routine lifts are generally, but not always, considered with generic risk assessments.

8.7.2

Risk Matrix

The Risk Assessment Matrix (RAM), A

ppendix 1 EP 2005-0264-GO1, shall be used to determine

the level of risk. If the risk is assessed

as red, the task shall not proceed. The lif

further control measures put in place to reduce the risk.

Page 27 of 247

t shall be re-assessed and

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

8.7.3 1.

AND HOISTING

10 Questions

SMEP.EP200802258279

MANUAL

REV.1.0

For a SAFE Lift

Are you aware of and fully c onversant with the

lifting and hoisting

procedures

applicable to the lift? 2.

Has everyone

3.

Has a pre-use inspection

involved with

this lifting of the lifting

operation attended equipment been c

the Toolbox

Talk?

arried out

and is the

load swings or

falls?

lifting

tackle tagged or marked with: •

Safe working load.

•

A uni qu e i de nt i f i ca t i o n num be r .

•

A v a l i d ce r t i f i ca t i o n da t e .

4.

Are all the safety dev ices working?

5.

Do you know the Person-In-Charge

6.

Is everyone

7.

Is there a curr ent Lift P lan and JSA, which

manages risks?

8.

Do you know the environmental

the lift?

9.

Is the lift ar

competent and

of the lift?

aware of his or her tasks?

ea controlled an

limits for

d is everyone

clear if the

10. Are signalling methods and communication agreed and clear to you?

8.8

Lift Categorisation

Lifting operations shall be categorised to reflect increasing risk and consequent increasing level of control required. The categories of lifting operations are as follows:

8.8.1

Routine Lifts

A g e ne r i c r i s k a s s e s s m e nt and l i f t pl a n m u s t be us e d f o r r o ut i ne l i f t s . H o w e v e r , c l as s i f y i ng a lifting operation as “Routine” does not automatically make it a

“Safe” lifting operation (most

incidents associated with lifting occur during “Routine” operations). The risk assessments and lift plan shall always be reviewed during toolbox talks for continued applicability. If t

here are

changes to the srcinal plan a further risk assessment must be undertaken.

8.8.2

Routine Lift

A R o ut i ne L i f t i s o ne whe r e : 1.

Uncomplicated

lifts that are performed

on a regular basis or

2.

Which involve

basic slinging

or

3.

The gross load does not exceed 5 tonnes,

practices

and not exceeding

50% of the manufacturer’s

capacity chart at the working radius. 4.

Only one lifting

Category

device is used for the lift.

of Lift

Control

Measures

Competent

Person

Lift Plan Reviewed by

Routine Crane Operations •

W i t hi n t he no r m al

•

Risk Assessment (generic)

Page 28 of 247

•

Crane Operator

•

Person in Charge (PIC)

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

operating parameters of

•

the crane. •

Lifting over a safe areas

•

Suitable environmental

•

•

•

SMEP.EP200802258279

MANUAL

REV.1.0

Lift Plan

•

Banksman

(generic)

•

Deck Crew

•

Drilling crew

•

Construction

J o b Sa f e t y A nal y s i s

conditions

•

Toolbox Talk

Familiar, competent

•

Safety checklist

crane operators

•

10 questions for

Load has known and

a safe lift

evaluated weight, shape and centre of gravity •

Standard rigging arrangements

Routine repetitive Lifting

•

Equipment (e.g. Drilling or

•

Construction Crews) •

Load has pre-determined

•

Single function or series of functions repeated

•

Order of function

Same equipment

•

Same operators

Routine Lifting Operations

Equipment used at the

Toolbox Talk

•

Safety checklist

•

10 questions for a safe lift

•

Same equipment

•

Stable known

•

•

Risk Assessment

•

Lift Plan (generic)

•

J o b Sa f e t y A nal y s i s

environment

•

Toolbox Talk

Familiar, competent

•

Safety checklist

equipment operators

•

10 questions for

Load has known and

a safe lift

evaluated weight, shape and centre of gravity •

•

(generic)

same location •

(PIC)

crew

A nal y s i s

with Loose Lifting Equipment •

Person in Charge

J o b Sa f e t y

•

repeated •

Lift Plan

•

(generic) •

w e i ght , s ha pe a nd c ent r e of gravity

Risk Assessment (generic)

Operations using the same

Standard rigging arrangements

Page 29 of 247

Maintenance Technicians

•

Drilling Crew

•

Person in Charge (PIC)

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

8.8.3

Non-Routine

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

– SIMPLE

A N o n- r ou t i ne Si m pl e L i f t i s o ne w he r e : 1.

It is not Routine

2.

The gross load weight does not exceed 25 tonnes,

as defined in 8.8.2 above, or and does not exceed 75% of the

manufacturer’s capacity chart, and 3.

Lift is in non-sensitive

or unrestricted

areas, and Load is with required

lifting

points or

easy to sling 4.

Only one lifting

Category

device is used for the lift.

of Lift

Control

Measures

Competent

Person

Lift Plan Reviewed by

Non-Routine – SIMPLE •

competent operator •

•

•

•

• •

Lift Plan

Load has known and

(prepared by

evaluated weight of < 25 tonnes

competent

Centre of gravity is

rigger) •

J o b Sa f e t y A nal y s i s

below sling attachments •

Risk Assessment

Use of certified lifting

•

Toolbox Talk

point directly above the

•

Safety checklist

load

•

10 questions for

A m pl e he a dr o o m Lifting in non-sensitive,

a safe lift

non-difficult or unrestricted area •

Single lifting appliance

•

Unlikely to be effected by changing environmental conditions

•

Experienced and competent operator

•

Standard rigging arrangements

•

Suitable lay down area available

•

Hoist suspended from a dedicated lifting structure or runway beam

•

•

(generic)

Equipment installed by

Lifts from one offshore v e s s e l t o a no t he r

Page 30 of 247

Maintenance technicians

•

Banksman

Level 1 & 2

•

Person in Charge (PIC)

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

8.8.4

AND HOISTING

Non-Routine

SMEP.EP200802258279

MANUAL

REV.1.0

– COMPLICATED

A C o m pl i ca t e d l i f t i s o ne w he r e : 1.

The load is an awkward shape or offset or a high centre of gravity,

2.

The load is fragile,

contains

3.

Two or more pieces of lifting

4.

Non-standard

5.

The gross load is greater

6.

The gross load represents w o r k i ng r a di us , o r

7.

The gross load is greater

liquid or is difficult equipment

crane configurations

or

to sling, or

are required

in unison i.e. tandem lifts, or

are used, or

than 25 tonnes,

or

more than 75% of the manufacturer’s

capacity

chart at the

than 25 tonnes and is also greater than 80% of the

manufacturer’s capacity chart.

Category

of Lift

Control

Measures

Competent

Person

Lift Plan Reviewed by

Non-Routine – •

COMPLICATED

•

operation with different

•

equipment (due to or unsuitability Use of two or more items of Lifting Equipment,

•

•

Lift Plan

•

Permit to Work

•

Toolbox Talk

•

J o b Sa f e t y

•

A nal y s i s

including tailing pipe using winch and crane

•

Safety checklist

(tandem lifting)

•

10 questions for

W i t hi n s e ns i t i v e , di f f i cu l t

a safe lift

or restricted areas •

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

•

A w k w a r d s ha pe , o f f s e t o r high centre of gravity, fragile, containing liquids

•

No lifting attachments and difficult to sling

8.8.5

Non-Routine

– COMPLEX

A co m pl e x l i f t i s o ne w he r e : 1.

Any of the above,

but with additional hazard

Technical Supervisor

(specific)

malfunction, inadequacy

•

Risk Assessment (Specific)

Continuation of a lifting

s, or

Page 31 of 247

Lift planner

•

Lifting Technical A u t ho r i t y

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

2.

The load is

3.

Lifting of

personnel, floating

lifted over, or

4.

The gross

load is greater than

5.

The gross load

MANUAL

near, operating

75 tonnes,

REV.1.0

equipment or

cranes, sub-sea

represents more

SMEP.EP200802258279

electrical power

lines, or

lifts, or

or

than 90% of

the manufacturer

75 tonnes and

is also greater

’s capacity c

hart at the

w o r k i ng r a di us , o r 6.

The gross load

is greater than

than 80% of

the

manufacturer’s capacity chart. Category

of Lift

Non-Routine - COMPLEX •

•

Control •

pack with method

operation with different

statement

personnel e.g. shift

•

HAZID

changeover

•

HAZOP

•

Dropped object

Lifting of personnel, Riding

study •

Over or in sensitive areas e.g. active or energised hydrocarbon

from one lifting

Professional engineer •

appliance to another •

In environmental conditions likely to effect equipment performance

•

Operator under training

•

Load with unknown or

Lift Plan prepared and reviewed by a

equipment. Transferring the load

Risk assessment (specific)

•

containing process

•

Formal work

Continuation of a lifting

including drill floor Man-

•

Measures

Lifting analysis per SES10.1

•

Work Permit

•

Toolbox Talk

•

10 questions for a safe lift

difficult to estimate w e i g ht a nd / o r ce nt r e o f gravity •

Load is special and / or expensive the loss of w hi ch w o ul d hav e s e r i o us impact on production operations

•

Non-standard rigging arrangements

•

Load lowered into or lifted from a confined space

Page 32 of 247

Competent •

Lift planner

•

Professional

Person

by •

Senior Structural Engineer

Lifting Technical A u t ho r i t y

Engineer •

Lift Plan Reviewed

and •

Structural TA1

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

•

Sub-sea lifting

•

Lifting involving floating

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

cranes Lifts involving floating cranes or Sub-sea lifting must be reviewed by the Structural TA1.

8.8.6

Non-Routine

– HEAVY

A he av y l i f t i s o ne w he r e : •

Category

The weight of the load is i appliance.

n excess of 90% of the rated

of Lift

Control

Measures

capacity of the lifting

Competent

Person

Lift Plan Reviewed by

•

W e i ght of l o ad i n e x c e s s

•

Lift plan

of 90% the rated capacity

prepared/review

of the lifting appliance

ed by a qualified engineer •

Risk assessment

•

J o b Sa f e t y

•

Crane

•

Operator •

Banksman

•

Rigger

Lifting Technical A u t ho r i t y

A nal y s i s •

Work Permit

•

Safety checklist

•

Toolbox Talk

•

10 questions for a safe lift

8.9

Execution

8.9.1

Permits

Prior to commencing lifting operations it must be ascertained whether a permit to work (PTW), as detailed in Permit To Work System procedure DIN: TCP.XX.1009, is required.

8.9.2

Pre-lift Meetings (Toolbox Talk)

A T o ol bo x T a l k s ha l l be he l d i m m e di a t el y be f o r e any l i f t t o e ns ur e t ha t a l l pe r s o nne l i nv ol v e d in the lift fully understand the JSA questions for a safe lift “

8.9.3

and Lift Plan. The PIC shall verify that t

he answers to “10

are all addressed.

Conducting

the Lifting Operation

The PIC shall ensure that lifting operations are carried out in s approved Lift Plan. Any variation from the agreed Lifting Plan shall result stopped and reassessed to ensure continued safe operation.

Page 33 of 247

trict accordance with the in the job being

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

9.0

Personnel Lifting

9.1

Purpose

SMEP.EP200802258279

MANUAL

REV.1.0

This section describes the requirements for the transfer of personnel by

personnel carrier and

w o r k i ng a t e l e v at e d he i g ht s f r om s u s pe nde d w o r k ba s k e t s / box e s and i s bas e d o n t he g ui da nce given in:

1. 2.

LOLER 98, Regulation BS 7121, Part 11

3.

ASME B30.23.

5.

Personnel carrier transfers and work basket operations are to be used in exceptional circumstances only, where no alternative means of carrying out the transfer of personnel or operation is available. In the situation where the transfer of

personnel between a

construction/pipelaying barge that is equipped with a helideck and a fixed offshore structure that is also equipped with a helideck is required, the

use of a helicopter is mandatory.

A t t e nt i o n i s dr a wn t o t he r e l ev ant s e c t i o ns o f t he S he l l gl o bal s t a ndar d o n l i f t i ng a nd hoi s t i ng EP2005-0264-GL-01 (Section 4.2.2) and EP2005-0264-ST.

SMEP’s preferred method for basket transfer is using the “FROG”. The

FROG is a semi-enclosed

basket. Personnel are seated in the centre facing outward while being secured by a four-point safety belt. It is Shell’ s policy to transfer personnel by means of basket only in exceptional cases (no other alternatives). In case another method than the FROG is applied, it has to be “equivalent” in terms of risk to personnel. A not he r a c cept a bl e m e t ho d f o r ba s k e t t r a ns f e r i s t he E SV A G T -R i g i d bas k e t . This basket has optical similarities to t

he conventional “Billy Pugh” design.

However, the ESVAGT-Rigid basket is, fully compliant with the British LOLER regulations and it requires a different procedure for personnel transfer as personnel stand during the transfer inside the basket.

Page 34 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

NOTE:

9.2

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

THE “BILLY PUGH” PERSONNEL TRANSFER CARRIER, SHOWN BELOW, IS NOT APPROVED FOR USE IN SMEP FOR PERSONNEL (PASSENGER) TRANSFER.

Scope

The scope of this section covers SMEP requirements for transferring people by personnel carriers and operating suspended workbaskets.

It specifies the requirements and defined instances where transfer by personnel carrier is allowed.

This standard prohibits a person from riding or travelling on a load, lifting

hook, sling,

platform or other lifting medium of a crane except in a specifically designed personnel transfer carrier that is solely used for that purpose. Attention is drawn to lifting and hoisting

9.3

Shell’s global standard on

EP2005-0264-SP-01

Authority

A l l per s o nnel ca r r i e r t r a ns f e r s s ha l l o nl y be c a r r i e d out u s i ng t he S M E P P e r m i t t o W o r k s y s t e m . To support the issuance of the permit to work, the utilised for each individual transfer (

attached carrier transfer checklist shall be

A ppe ndi x 5 ) .

For guidance on how to complete the work permit refer to DIN: TCP.XX.1009“Permit to Work System”

9.4

Prerequisites

If a personnel transfer operation is to be carried out the foll operation can start: •

Permit to Work.

•

Risk Assessment.

•

Lift Plan. (Written step-by-step instructions)

•

Safety Check List.

Page 35 of 247

owing must be produced before the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

9.5

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Objectives

Carrier transfers are not the preferred method of moving personnel. However, it is recognised that there are situations where this method of t

ransfer may be justified. All carrier transfers

must be covered by an appropriate SMEP Permit to Work, Risk Assessment and Lift Plan, and be conducted in accordance with this section.

9.6

Procedures

The contractor shall provide a procedure for personnel lifting. The procedure shall be forwarded to SMEP’s Lifting Technical Authority for review.

9.7

Defined Cases

Personnel transfer by personnel carrier shall only be allowed in the following defined cases 1.

When locating

a Jack Up to a platform

2.

Between

3.

For the purpose

of vessel inspection

4.

Upon the initial

arrival and/or final departure

MOU and a securely

prior to the establishment

moored cargo barge alongside during MOU location

: of a gangway.

e.g. Helideck

lift.

moves.

of a tender assisted

rig at/from

an

SMEP platform. Prior to/after establishment of access between the rig and platform using the rig’s personnel bridge. 5.

In case of emergency.

6.

During the construction/installation

of a new platform/jacket

when the only access is

by personnel carrier. In any other cases, where carrier transfers are deemed to be necessary, prior approval shall be obtained from SMEP’s HSE department and Lifting Technical Authority. NOTE:

UNDER NO CIRCUMSTANCE SHALL THE “PERSONNEL CARRIER” BE USED AS A WORKBASKET.

9.8

Emergency

Conditions

Personnel may be transferred under emergency conditions where the risk of not transferring is considered greater than the risk of transfer. While it can be may arise, it is not practicable to try and envisage all

foreseen that such circumstances possible cases and list them.

W e a t he r a nd o t he r l i m i t a t i o ns f o r w e a t her c o ndi t i o ns wi l l be m ade by r i s k a s s e s s m e nt o n a case by case basis by those involved in the

transfer, but shall not exceed those governing

crane operations or the launch of fast rescue craft.

9.9 1.

Risk Assessment All personnel

carrier lifting

operations

must be subject to a risk assessment

and a lift

plan 2.

The risk assessment

shall identify

all reasonably

foreseeable

hazards and failure

scenarios, including crane operators state of mind, so that in all operations of the transfer personnel are protected from being crushed, t rapped, struck or fall from the carrier. 3.

A written

lift plan must be completed

for the operation.

Page 36 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

4.

Emergency

AND HOISTING

procedures

SMEP.EP200802258279

MANUAL

shall be established

REV.1.0

e.g. emergency

lowering

in the event of

crane breakdown, sudden change in sea/weather conditions. 5.

Appropriate

crane and carrier checks to be recorded

on the plan.

6.

The Person In Charge (PIC) must carry out the checks and supervise

the operation

defined in the lift plan.

9.10 1.

Other Considerations Immediately

before the lift the crane operator

must check that the prevailing

conditions e.g. wind speed and sea state criteria listed

in

weather

9.12 .

2.

Check that other criteria required for the operation are met e.g. passengers are w e ar i ng l i f e j a ck e t s o r a n a ppr o v e d f l o t a t i o n wo r k v e s t , a nd ha v e be e n br i ef ed o n a l l

3.

The area below the path of the carrier shall be kept clear of personnel.

aspects of the transfer and are willing to transfer.

9.11

Criteria

9.11.1

Crane Suitability

1.

The crane is certified.

2.

The certificate

issued by the surveyor

shall clearly indicate

that the crane is suitable

for personnel transfer (man-riding) and fully complies with the requirements of Lifting Operations and Lifting Equipment regulations (LOLER 19198) or ASME B30.23. 3.

SMEP Lifting

Technical

Authority

must approve cranes for use in personnel

carrier

transfer duties, and shall review all certification and maintenance records pertaining to the crane. 4.

Loading

5.

All connections

hooks shall be of the design that can be closed and locked. between

the crane and the personnel

cannot be accidentally self-released under any 6.

Cranes or winches,

which are suitable

carrier shall be such that they

circumstances. for personnel

lifting

operations,

shall be clearly

marked at the operator’s location “SUITABLE FOR MAN RIDING” or “ SUITABLE LIFTING PEOPLE”. Cranes with a capacity of less than 10 tonnes capacity of less than 3 tonnes shall not 7.

Mobile cranes operating

FOR and/or winches with a

be used for personnel lifting operations.

on marine vessels

shall

N O T be used for the transfer of

personnel (refer to Section 11.5.5).

9.11.2

Personnel

Transfer Carrier

1.

The carrier shall be certified

2.

The certificate

and be included

issued by the surveyor

in the ship’s Register

shall clearly indicate

of Lifting

Gear.

the carrier is suitable

personnel transfer. 3.

Personnel

carriers

must be of an approved

design and approved

Technical Authority

Page 37 of 247

by SMEP’s Lifting

for

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

4.

Two tag lines shall be attached

5.

There shall be no knots on the tag lines to minimise

6.

The transfer

carrier lifting

to the carrier,

of a suitable

length.

the chance of snagging.

gear, master links, slings etc. shall have a factor of safety

of at least 10. The carrier shall be

equipped with a double safety load line assembly

composed of a main wire rope sling and a secondary shock absorbing safety line. The capacity of the wire rope sling and the secondary shock absorbing safety line shall be such that either the sling or the safet

y line shall be able to carry the full l

oad including

the safety factor. 7.

A length of 10metres

8.

The shackle

is recommended

for the pennant.

type to be used is bow or anchor type fitted with split pins i.e. bolt, nut

and split pin. 9.

An anti-spin

device shall be fitted between

master link. The anti spin device shall have a 10.

The worksite

supervisor

11.

The carrier shall be thoroughly

inspected

1.

prior to each use.

every 6 months and load tested every 12

the personnel carrier manufacturer.

SCISSOR ACTION SPRING-LOADED OR SELF-LOCKING HOOKS SHALL NOT BE USED (REF. FIG. 16A) FOR PERSONNEL LIFTING OPERATIONS

9.11.3 1.

carrier upper

safety factor of at least 10 to

shall perform inspections

months or as recommended by NOTE:

the load and the personnel

Vessel Suitability The type of vessel considered

suitable

to carry out a transfer

ability to maintain station alongside the plat

is determined

by its

form and the amount of clear deck space

available to safely receive the carrier. 2.

Vessels

with an A-frame

at the stern. Or without side railings

are not considered

suitable for carrier transfers. For SMEP this excludes the use of General Purpose mooring launches (Pilot Launches, Survey boats wit

h A-frame and landing craft. Other

v e ss e l s m ay a l s o be f o und uns ui t abl e de pe ndi ng u po n s t at i o n k e e pi ng a bi l i t y a nd de ck (obstruction) load status. 3.

Marine vessels

used for personnel

carrier transfer

operations

must be approved

by the

marine Technical Authority.

9.11.4 1.

Take-off and landing area The take-off

and landing

area shall be level, free from obstructions,

and have a non-

slip surface. 2.

The minimum clear space on the installation

shall be 4.5metres

by 4.5metres

in any

we a t her co ndi t i o ns . 3.

The minimum clear space on a vessel shall be 6 metres by 6 metres in any weather conditions.

4.

The minimum clear space with vertical

obstructions

Page 38 of 247

must be as follows:

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

(a) With a single vertical obstruction of 1.5 metres at the perimeter of the landing area, the clear area shall be 4.5 metres diameter. (b) With a single vertical obstruction of 2.5 metres at the perimeter of the landing area, the clear area shall be 7 metres in diameter.

9.12

Environmental

9.12.1

Weather

The weather criteria and maximum MOU or vessel movement for all personnel lifting operations shall be as follows: Mean wind velocity : 10 m/s measured at 10 metres above sea. Mean wind velocity

: 6m/s measured side.

W a v e he i g ht Significant

10 metes above sea if working on the weather

: D e t e r m i ne d by t he a bi l i ty of t he v e s s e l t o ho l d s t a t i o n.

wave height

: Not more than 2 metres

Maximum roll (MOU)/vessel

: 3 degrees

The master of the attending vessel shall

demonstrate that the above weather criteria are met at

all times during transfer operations and shall demonstrate that the

vessel can hold station

w i t hi n a 5 m et r e r a di us f o r a t l e a s t 2 m i nu t e s pr i o r t o e ac h t r a ns f e r . S M EP m a r i ne de pa r t m e nt shall verify all sea state values.

9.12.2

Visibility

Horizontal visibility must be considered and shall be a minimum of 500 metres. Vertical v i s i bi l i t y s hal l be s u ch t ha t t he t i p o f t he c r a ne bo o m i s a l wa ys i n v i ew by t he cr a ne o pe r at o r . A ppr o v al f r o m a l ev e l 4 m a nag e r m us t be o bt a i ne d f o r a ny ni ght t i m e t r ans f e r s .

9.12.3

Daylight

Transfer operations, wherever possible, be conducted

during daylight hours. In urgent cases,

w he r e ni ght t i m e t r a ns f e r s a r e f e l t unav oi da bl e , t he pr o v i s i o n o f s e a r c hl i ght s t o e nabl e t he crane operator to have adequate visibility throughout personnel transfer path and landing areas; the wearing of clothing with retro-reflective tape by those being transferred and recovery arrangements shall be addressed. that the risks are

as low as

For night time transfers,

A risk assessment shall be performed that shows

reasonably practicab

the weather criteria

le (ALARP).

and maximum MOU

or vessel movement for

personnel lifting operations shall be: Mean wind velocity

:

5 m/s measured

Significant

:

Not more than 1.5 metres

:

3 degrees

wave height

Maximum roll (MOU)/vessel

Page 39 of 247

all

at 10 metres above sea.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

9.12.4

AND HOISTING

Rainfall and Electrical

SMEP.EP200802258279

MANUAL

REV.1.0

Storms

If the transfer is proposed during a period of rainfall or electrical storm, considerations shall be given to the severity of the

weather, and the transfer postponed if there are any concerns

that it could affect the transfer. In all cases, when any of the above

environmental conditions are exceeded all transfer

activities shall cease immediately and transfer activities resume when environmental conditions return to an acceptable value.

9.12.5

Communications

Radio communication shall be established

between Worksite Supervisor, Crane Operator,

Master of the Vessel and Banksman. The Crane Operator radio communication shall be hands free, he shall have a full and unobstructed view of t he take off and landing area as well as

the

full lifting trajectory. However the Banksman must be on hand to take control of signalling in the

event that the crane

operator loses visual contact with the “carrier”.

9.13 9.13.1

Personnel Crane or Winch Operator

The Crane Operator shall meet the competence requirements of Lifting Equipment Management System (EP200803208668)- and have a minimum of 50 operating hours (logged) operating the crane to be used in the personnel carrier operation. The crane or winch operator shall not leave the crane or winch controls throughout the duration of the personnel lifting operation. He shall solely concentrate his attention to the personnel lifting operation in progress.

9.13.2

Banksman

The Banksman shall meet the competence requirements of Lifting Equipment Management System (EP200803208668) he shall be easily identified by

a brightly coloured banksman jacket. He

shall also carry a working radio by which to communicate as described in 9.12.5 above.

9.13.3

Assisting

Personnel

A s s i s t i ng pe r s o nne l s ha l l co ns i s t o f t w o as s i s t ant s a t t he t a k e o f f a nd l a ndi ng a r e a s

9.13.4

Personnel

Transferring

by Carrier

Personnel being transferred must be properly attired for offshore work i.e. safety helmet with chinstrap, safety footwear, safety glasses, long sleeved coveralls and approved floatation device. Have been briefed on the transfer procedure, viewed the transfer video and signed acceptance for transfer form. See Appendix 6. Personnel will only undertake the carrier transfer on a voluntary basis. If they do not wish transfer, they must not be forced to do so.

Page 40 of 247

to

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

A n e x pe r i e nce d pe r s o n s ha l l a l w ay s ac co m pa ny a n i ne x pe r i e nc e d pe r s o n o r t ho s e not t r ai ne d in the use of the personnel

9.14

carrier.

Bags

Hand luggage up to a maximum of 29kg (that can be strapped in place) may be transported inside the carrier. All other luggage, bags, oversized bags and tools shall

be transported

separately as cargo in a cargo box or other suitable container.

9.15

Toolbox Talk

Toolbox talks shall be held prior to

the transfer, this will involve (crane side) t

he Person in

Charge, Crane Operator, Banksman and assistants boat master via radio in necessary. Similarly, the boat Master shall brief his crew. The included in the toolbox talk:

following elements of the transfer shall

•

Safe loading conditions

•

Crane actions, movements and signals

•

Body positions, pinch points and personal stability

•

PPE requirements

•

Safety aspects of the transfer – swing, escape routes etc.

•

Potential emergency situations and recovery/rescue procedures are in place

•

Expected behaviour of personnel being t

9.16

be

ransferred.

Recovery Arrangements

A r e s cue pl a n s ha l l be pr e pa r e d f or a l l pe r s o nne l l i f t s a s pa r t o f t he L i f t P l a n. Al l pe r s o nnel and equipment required to implement the rescue plan shall be readily available prior to and during the lift i.e. Fast Rescue Craft (F

RC) must be on standby in the water to effect

a speedy

recovery if personnel fall into the sea. Rescue operations can introduce their own hazards, therefore the planning and execution of a rescue requires particular care and attention including additional risk

assessment before

proceeding.

9.17

Vessel Propellers

The lowering and hoisting of a personnel carrier near the propellers of a ves as much as is practically possible.

9.18

Planned Maintenance

Refer to Section 4.

9.19

Administration

and Operational

Page 41 of 247

Duties.

sel to be avoided

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

9.19.1

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

SMEP Site Representative

The SMEP Site Representative shall be: 1.

Familiar

with the carrier transfer

2.

Satisfied

with the fitness

requirements.

3.

Satisfied

with the suitability

4.

Satisfied

with the visibility

5.

Satisfied

with the landing

6.

Check the crane or winch and carrier have current valid Inspection

Certificates.

7.

Check the crane or winch and carrier are registered

for personnel

8.

Check suitability

9.

Ensure participants

and training

of the personnel

to be transferred.

of the MOU. and sea conditions. area

carrier transfer with SMEP Lifting

and approved

Technical Authority.

of wind speed for crane operations. are briefed and understand

the requirements

of carrier transfer

and have signed the transfer form. 10.

Ensure the Master of the vessel is familiar

with the carrier transfer

requirements

and is

briefed accordingly. 11.

Ensure that the Supervisors

and Banksman

requirements and handling of the 12.

Have verified

13.

Ensure communications

the competency

are familiar

with the carrier transfer

carrier. and experience

are established

of the crane operator.

with all the parties

Master of the vessel, Officer supervising the boat desk, t

involved

in the transfer.

The

he crane operator and the

supervisor on the installation. 14.

Verify the Fast Rescue Craft (FRC) cover is provided.

15.

Have carried out Risk Assessment.

16.

Authorise

and sign the work permit,

transfer

request and transfer

checklist

for the

carrier transfer.

9.19.2

Master of the Vessel

Shall confirm to the SMEP site representative

the following

Check

1.

Must confirm boat is suitable for basket and that he can hold station for the duration of w e a t he r a nd s e a co ndi t i o ns .

2.

He accepts

3.

Have confirm ed that the d eck crew understand the and have been fully briefed.

4.

Two deck hands on deck to handle tag

5.

The Banksman is identified with a highly reco gnised vest and communication and establishes communication on a dedicated

has a ra dio for channel.

6.

Confirm that

area requirements

the transfer and

the landing area

transfer and a pproved by Marine dept. the transfer in the prevailing

understands the requ

irements for c

arrier transfer.

carrier transfer

requirements

line.

is clear, and

meets the landing

Page 42 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

and is in a safe and clean condition. 7.

The people to

8.

Confirm that

9.19.3

be transferred

have been br

the person(s)

iefed and signed

transferring is/ar

the transfer form

e fit to undertake the

.

transfer.

Banksman and/or Deck Foreman

Shall confirm to the SMEP site representative requirements

the following

Check

1.

The transfer

are understood

2. 3.

The personnel c arrier is ch ecked, suitable for the transfer and is cor rectly rigged. The personnel transferring are fit for the transfer and understand the requirements; a demonstration of how to use the carrier will be given if required and signed the transfer form.

4.

Communications

5.

Have full view of the transfer

6.

Landing area

7.

The Banksman

is clearly

8.

Toolbox meeti

ng held with all parties involved.

9.

2 riggers/deckhands

have been established. areas.

meets the requirem

ents , is clear and is

in a safe condition.

identified.

to handle tag lines.

10. Only certified and marked equipment is used in the transfer. 11. The personnel are wearing the correct PPE.

9.19.4

Crane Operator

Shall confirm to the SMEP site representative

the following

Check

The crane is fully operational. The wind speed is satisfactory for safe operation f The requirements

for carrier transfer

or carrier transfer

have been

understood.

A f ul l and uno bs t r uc t e d v i e w o f t he B a nk s m an a nd t he t r a ns f e r l a ndi ng a r e a o n bo t h sides. Confirm that the landing area is clear. Communications have been established. Daily crane checks have been completed and signed by the crane operator. The personnel carrier and lifting gear are in a safe state of That the crane will carry no other load that the

repair before use. personnel carrier.

That the logbook entry will be made for each lift. That he has no personal conflict with any

9.19.5

Riggers/Deck

of the personnel being lifted.

Hands

Shall confirm to the Banksman/Deck Foreman the following: 1.

Have been briefed and understood

2.

Familiar

with handling

the carrier transfer

the tag lines.

Page 43 of 247

requirements.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

Know how to control

4.

Follow instructions

9.19.6

Personnel

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

the swing with the tag lines. from the Banksman/Deck

Foreman in charge of the operation.

Transferring

Shall confirm to SMEP site representative the following: 1.

Have been briefed and understand

the carrier transfer

requirements

and signed the

transfer form. 2.

Agreed to the transfer

3.

Are physically

by carrier.

fit and to declare if they suffer from Vertigo

(fear of heights),

seasickness etc. 4.

Understand

5.

Familiar

that the transfer

is purely on a voluntary

with the method of carrier transfer

basis.

and has been briefed

on the method of

transfer. 6.

Observe

7.

Insist on being accompanied

9.19.7

all instructions

from those in charge of the operation. by an experienced

person if transferring

for the first time.

Crane owner’s Requirements

The owner of the crane used to transfer personnel in

a transfer carrier shall ensure that:

The crane is registered and approved for personnel basket transfer with SMEP’s Lifting Technical Authority. A l og boo k i s a v a i l a bl e t o ena bl e t he cr a ne o pe r at o r t o m a k e e nt r i e s o f e a ch l i f t . This logbook must be made available for inspection on request.

9.19.8 1.

General Precautions Moving the personnel

carrier shall be only under powered conditions

in a slow

controlled, cautious manner. 2.

The load line hoist drum shall have controlled apply in neutral position.

load lowering.

Free fall is not allowed

Automatic

brake shall

.

3.

The total weight including personnel transfer carrier, rigging and occupants exceed 50% of the crane's rated capacity for the radius and configuration used.

4.

Rigging

used for personnel

hoisting

shall not

must not be used for any other purpose and shall

be kept apart from other rigging and clearly identified as only to be used for personnel hoisting. 5.

The rigging must be capable

of handling

10 times the maximum intended

Page 44 of 247

load.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

9.19.9

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Pre-Use Inspection

A pr e- i ns pe ct i o n of t he pe r s o nne l t r a ns f e r ca r r i er s ha l l be unde r t ak e n a t t he s t a r t of e a ch day the personnel carrier will be used. The pre-inspection shall be carried out in accordance with W o r k I ns t r u ct i o n.

9.19.10

Trial Lifts

A t r i al l i f t w i t h t he un o c cup i e d pe r s o nne l t r a ns f e r ca r r i e r s ha l l be u nde r t a k e n at t he s t a r t o f each day the personnel carrier will be used. A f t e r t he t r i a l l i f t a nd j us t pr i o r t o ho i s t i ng t he pe r s o nne l , t he ca r r i e r a nd r i g gi ng s ha l l be hoisted a few centimetres and inspected by the PIC.

Reflex Marine Frog transfer

9.20

unit

Man Riding (drilling

Esvagt-Rigid

basket

operations)

Manriding should always be avoided and alternatives should have been challenged. However if properly assessed and man riding will be required then only competent persons and dedicated Man Riding winches, which incorporate appropriate safety equipment, shall be used for Man Riding. These winches shall be clearly marked ‘DEDICATED FOR MAN RIDING’

and never used

for any other purpose. A dedicated team including the PIC, Winch Operator, and person being lifted, shall carry out the operation. The PIC shall ensure that

no other operation that could

interfere with the Man Riding is carried out. Prior to installing or certified for Man Riding the following shall 1.

A suitable

and sufficient

using winches that are

be in place:

risk assessment

shall be carried out to iden tify all reasonably

foreseeable hazards and failure scenarios such that in all operations using Man Riding w i nche s t he pe r s o n i s pr o t e ct e d f r o m be i ng c r u s he d, t r a ppe d, s t r u ck o r f a l l i ng f r om t he carrier. Measures additional to those mentioned in this Section shall be

put in place if

the risk assessment identifies circumstances in which additional controls are required; 2.

Emergency

means shall exist

by which all winch motion can effectively an

brought to a halt;

Page 45 of 247

d rapidly be

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

A c omprehensive

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

review shall be made by the PIC to e nsure that the safety featur

the winch are adequate to provide a safe method of operation for the M operation. No Man Riding shall be allowed if

es of

an Riding

the Winch Operator does not have clear

sight of the rider. Man Riding below the derrick floor level

is not allowed. It requires a

separate Man Riding winch mounted below the floor. Man riding above the monkey board level shall not be permitted. Use of Man Riding harnesses s

hall only be allowed for short durations with authorisation of the

Site Manager. Refer to (Yellow Guides) ‘Working at Height’ for

maximum permissible times and

recovery periods. The maximum time suspended in the Man Riding harness must always be determined in the risk assessment, taking into account manufacturers instructions, gender and physical condition of the manrider. Only full body harnesses shall be

used. Harnesses shall

never be used for lifting personnel for long duration jobs, as the constricting the blood supply vessels in the legs.

potential exists for

A secondary fall protection device shall be

used, independent of the primary lifting mechanism. A s pl i t pi n s ha l l be us e d o n t he s ha ck l e be t w ee n r i di ng be l t a nd w i nch w i r e . I t s ha l l not be possible for the split pin to

fall out during use. Other types of pin shall not

be used.

Use, maintenance, storage, check, inspection and examination of riding belts shall as

a

minimum comply with manufacturer’s instructions for use, see also EN 813 and EN 365.

9.20.1

Winches for Man Riding

W i nche s t ha t ar e t o be us e d f o r M a n R i di ng s ha l l hav e t he f o l l ow i ng f ea t ur es a nd s e t t i ng s : 1.

A second independent

brake shall be provided

for use if the automatic

brake fails. This

brake should be manual unless the second automatic brake is completely independent of the automatic braking system; 2.

Equipment

shall be incorporated

in the winch system to

prevent the carrier from over-

riding and over speeding; 3.

Maximum pull limiting

feature.

The limi t sh all b e set to the v alue determined

during the

risk assessment for the job; 4.

The winc h shall be capable

of lowering in

a c ontrolled m

anner in the event of sudden

loss of power or primary control; 5.

The winch shall have adequate

capacity

to handle the loads required

include but not be limited to: 1.

Weight of passengers;

2.

Tare weight of the carrier;

3.

Rope weight and frictional

effects.

Page 46 of 247

which should

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

The design factor for the winch and the wire rope, taking into

REV.1.0

account the sum of these

w e i ght s , s ha l l no t be l e s s t ha n 8 : 1 . 6.

Suspension

points for sheaves in the winch systems

shall be rated to withstand

the

maximum credible winch pull; 7.

The design of the winch should be supported

by a FMEA (Failure

Modes and Effects

A n al y s i s ) ; 8.

The winch

shall be equipped

with a gu ard over the drum that provid es protection

to the

W i nch O pe r a t or e . g. , i n t he e v e nt o f r o pe br e a k ag e , but do e s no t i nhi bi t t he o pe r a t o r from monitoring the spooling action of the rope on the 9.

drum;

Wire rope used in Man Riding winches shall b e of the non-rotating

type or as identified

by the manufacture; The ratio (D/d) between sheave diameter (D) and the wire rope diameter (d) s than 22.

Page 47 of 247

hall not be less

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

10.0 Su spended Work Baskets (Cranes) Suspended workbasket operations are not the preferred method of carrying out work at elevated heights. However, it is recognised that there are s

ituations where this method of

operation may be justified; suspended workbasket operations offshore are forbidden. All suspended workbasket operations must be covered by

an appropriate SMEP Shell Permit to

W o r k , R i s k A ss e s s m e nt and L i f t P l a n, a nd be co nduc t e d i n a cco r danc e w i t h t hi s s t anda r d. The following information is based on the guidance given in: 1.

LOLER 98, Reg 5

2.

ASME B30.23

3.

HSE Safety Notice 1/97

10.1

Requirements

The following covers the basic safety requirements that must be met when

personnel are

required to work from a ‘suspended work basket’ that has been raised by a mobile crane.

10.2

Equipment

A l l l i f t i ng t ac k l e us e d i n t he l i ft m u st ha v e s a f e t y co e f f i ci e nt o f at l e a s t t wi c e t ha t r e qu i r e d f o r general lifting. The workbasket and associated lifting equipment and lifting tackle must be marked with it

s

respective SWL, identity and correct colour code. All lifting equipment and lifting tackle to be used in the operation must be pre-use inspected. The crane shall be uniformly level within 1% o

f level and shall have firm footing under both

crawler tracks or all outrigger pads. W he r e a cr a ne i s us e d t ha t ha s l o ad-l i m i t i ng a nd/ o r s l a ck w i r e cut - o ut dev i ce , t he co r r e ct operation of these devices must be confirmed before the crane is used. Before starting the operation ensure that the wire rope is spooled correctly on the If the operation Risk Assessment identifies

drum.

that there is danger from falling objects, or a

danger of striking overhead objects as the ‘suspended workbasket’ is raised, suitable overhead protection for personnel in the carrier must be provided. If the workbasket has access doors they must open in-wards and must have a device to prevent inadvertent opening. Suitable high edge guardrails must be fitted to the workbasket to prevent personnel from falling from the workbask

et. The floor of the workbasket

To cover the event of a failure to

must have a

non-slip surface.

the primary lifting system with personnel suspended, a

secondary system capable of safely lowering the workbasket, or personnel from the workbasket, must be available. W he r e a ppr opr i a t e wa r ni ng l a be l s m us t be a t t a che d to e qu i pm e nt t o i ndi ca t e k no w n da ng e r s . Labels shall also be fitted to

10.3 1.

warn against incorrect usage.

Personnel All personnel

involved

in suspended

workbasket

Page 48 of 247

operations

must have:

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

2.

AND HOISTING

a.

Agreed to do so.

b.

Have received

c.

Be fully conversant

adequate

SMEP.EP200802258279

MANUAL

instruction.

with the requirements

Confirm that all personnel

REV.1.0

in the workbasket

involved. are wearing appropriate

Personal

Protective Equipment (PPE). 3.

The Risk Assessment

must consider

the practicability

arresters anchored on the workbasket safety 4.

of issuing

personnel

with fall

anchorage points.

Personnel

in the workbasket must have a primary means of communication/attracting attention (e.g. hand-held radio) and a back-up system (e.g. whistle) if assistance is required.

10.4

Personnel Only)

10.4.1

Engaged in Suspended

Work Basket Activities

(Onshore

Authority

A l l s us pe nde d wo r k ba s k e t op e r a t i o ns s ha l l o nl y be c a r r i e d o ut us i ng t he S M E P P e r m i t t o W o r k system. To support the issuance of the permit to work, the

attached suspended workbasket operations

checklist shall be utilised for each individual operation (

A ppe ndi x 6 ) .

For guidance on how to complete the work permit refer to DIN: TCP.XX.1009, “Permit to Work System”.

10.4.2

Prerequisites

If a suspended workbasket operation is to be carried out the following must be produced before the operation can start: 1.

Permit to Work.

2.

Risk Assessment.

3.

Lift Plan. (Written

4.

Safety Check List.

10.4.3

step-by-step

instructions)

Risk Assessment

A l l s us pe nde d w o r k ba s k e t o pe r a t i o ns m us t be s ubj e c t t o a r i s k a s s e s s m e nt ( R e f e r E 9 5 -0 3 1 1 ) and a lift plan. The risk assessment shall identify

all reasonably foreseeable hazards and failure scenarios

such that in all suspended workbasket operations the people are protected from being crushed, trapped, struck or falling from the

workbasket.

A ppr o pr i at e cr a ne and w o r k ba s k e t che c k s t o be r e co r de d i n t he pl an. A pe r s o n i n char ge ( P I C ) s ha l l c ar r y o ut t he c he ck s a nd s upe r v i s e t he o pe r at i o n de f i ne d i n t he lift plan.

Page 49 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.4.4 1.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Other Considerations To prevent personnel

from walking

beneath the suspended

workbasket

the area beneath

the workbasket must be cordoned off. 2.

That other criteria

required

for the operation

are met, e.g. personnel

body harness, and they have been briefed on all facets of

10.5

full

Criteria

10.5.1 1.

are wearing

the operation.

Crane Suitability A lifting

surveyor

from an independent

third party certification

authority

shall certify

the crane. 2.

The certificate

issued by the lifting

surveyor

shall clearly

indicate

the crane is suitable

for man-riding and fully complies with the requirements of ASME B30.23 or Lifting Operations and Lifting Equipment Regulations (LOLER 1998). 3.

SMEP’s Lifting

Technical

Authority

must approve cranes used for suspended

workbasket

operations and shall review all certification and maintenance records pertaining to the crane. 4.

Load hooks shall be of the design that can be closed and locked.

The mousing of the

hook opening is not permitted. 5.

All connections

between

the crane and the suspended

they cannot self-release under any 6.

Articulating or truck loading duties and shall not be used,

workbasket

shall be such that

circumstances. cranes (HIAB trucks) are not suitable

for man-riding

Cranes, which are suitable for personnel lifting operations, shall be clearly marked at the operator’s location “SUITABLE FOR MAN RIDING” or “SUITABLE FOR LIFTING

PEOPLE”. Cranes

w i t h a ca pa ci t y of l e s s t ha n 1 0 t o nne s s ha l l no t be u s e d f o r s us pe nded w o r k ba s k e t o per a t i o ns .

10.5.2 1.

Work Baskets A surveyor

from an independent

third party certification

authority

shall certify

the

wo r k ba s k e t . 2.

The certificate

issued by the surveyor

shall clearly indicate

the workbasket

is suitable

for suspended work activities. 3.

SMEP’s Lifting

Technical

Authority

must approve the work basket used and shall review

all certification and maintenance records pertaining to the work basket. 4.

The purpose-built

workbasket

shall be designed

to an International

Standard

14502-1, AS 1418 or ASME B30. 23 or equivalent. 5.

Two taglines

6.

There shall be no knots on the tag lines to minimise

shall be attached

to the workbasket,

Page 50 of 247

of a suitable

length.

the chance of snagging.

i.e. BS EN

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

7.

The workbasket

AND HOISTING

lifting

SMEP.EP200802258279

MANUAL

REV.1.0

gear, master links, slings,

least 10. The workbasket shall be equipped with a

etc. shall have a factor of safety of at double safety load line assembly

composed of a main wire rope sling and a secondary shock absorbing safety line. The capacity of the wire rope sling and the secondary shock absorbing safety line shall be such that either the sling or safety li

ne shall be able to carry the full load including the

safety factor. 8.

The shackle

type to be used is the bow or safety-anchor

type fitted with split pins, that

is, bolt, nut and split-pin. 9.

An anti-spin

device shall be fitted between the load line and the workbasket

master link. The anti spin device shall have a 10.

The worksite

11.

The workbasket

Supervisor

twelve months or as NOTE:

10.6 10.6.1

factor of safety of at least 10

shall perform subsequent

shall be thoroughly

inspected

inspections

upper to 1.

prior to each use.

every six months and load tested every

recommend by the workbasket manufacturer.

SCISSOR ACTION SPRING-LOADED OR SELF LOCKING HOOKS SHALL NOT BE USED FOR PERSONNEL LIFTING OPERATIONS. REFER FIG 16.

Environmental

Conditions

Weather

The weather criteria for all personnel lifting operations shall Mean Wind Velocity

:

8 m/s measured

be as follows: at 10 metres above ground level.

The person in charge shall ensure that the above weather criteria is fully

met at all times

during the operation.

10.6.2

Visibility

Horizontal visibility shall be considered, and shall be at l shall be such that the tip

10.6.3

east 500 metres. Vertical visibility

of the crane boom is always in full view by t

he crane operator.

Daylight

W o r k ba s k et ope r a t i o ns s hal l o nl y be c ar r i e d o ut du r i ng da y l i g ht ho ur s .

10.6.4

Rainfall & Electrical

Storms

If the workbasket operation is proposed during a period of rainfall or electrical storm, consideration shall be given to the severity of

the weather, and the operation postponed to

more favourable conditions if there are any concerns that it could effect the operation. In all cases, when any of the

above environmental conditions are exceeded, all activities shall

cease immediately, and workbasket activities may only resume when the environmental conditions return to acceptable values.

Page 51 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.7

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Communications

Radio communication shall be established between Person in Charge, Crane Operator (hands free), Banksman and the lifted personnel. The crane operator shall have

a full and unobstructed

v i e w o f t he w o r k ba s k et ope r at i ng ar e a .

10.8

Crane

The Crane Operator shall hold a current, valid mobile crane operator's certificate, from a SMEP approved training provider, and have a minimum of 6 months experience as a crane operator. The Crane Operator shall also have a minimum of 50 operating hours (logged) operating the crane to be used in the suspended workbasket operation. The crane operator shall not leave the crane controls throughout the duration of the suspended workbasket operation. He shall solely concentrate his activities on the s

uspended workbasket operation in

progress.

10.9 Personnel 10.9.1

Banksman

The Banksman shall hold a current, valid banksman’s certificate from a SMEP approved training facility and have experience of workbasket lifting operations. The banksman shall be easily identified by a also carry a working radio by which

brightly coloured banksman’s jacket. They shall they can communicate as described under 9.4

“Communications” above.

10.9.2

Personnel

Working from the Work Basket

Personnel working from the workbasket must be properly attired this includes safety helmet with chinstrap, safety footwear, coverall and approved full body harness. Personnel will only undertake work on a voluntary basis. If they do not the workbasket, they will not be forced to do so.

wish to work from

See A ppe ndi x 6

A n e x pe r i e nce d pe r s o n s ha l l a l w ay s ac co m pa ny i ne x pe r i e nce d pe o pl e o r t hos e no t t r a i ne d i n the use of suspended workboxes.

10.10

Tool Bags

Only the required tools and materials required to carry out the task shall be allow

ed in the

w o r k bas k e t .

10.11 Safety 10.11.1

Toolbox Talk

Toolbox talk shall be held prior to t

he personnel being hoisted, this will involve t

Charge, crane operator and personnel to be hoisted the following elements of t shall be included in the toolbox talk:

Page 52 of 247

he Person in he operation

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

•

Crane actions, movements and signals.

•

Body positions, pinch points and personal stability

•

Personnel protective equipment requirement

•

Safety aspects of the operation – Basket swing, Escape routes etc.

•

Potential emergency situations

•

Expected behaviour of personnel being hoisted

10.11.2

Recovery Arrangements

A r e s cue pl an s ha l l be pr epa r e d f or a l l pe r s o nnel ho i s t i ng o pe r at i o ns . A l l e qui pm e nt r e qui r ed to implement the rescue plan shall be

readily available prior to and during the operation.

Rescue operations can introduce their own hazards; therefore the planning and execution of a rescue requires particular care and attention including additional risk

assessments before

proceeding.

10.12 10.12.1

Maintenance Planned maintenance

To ensure safe and satisfactory operation of the crane and workbasket, a properly planned maintenance system shall be established and used. Refer t

o IMP 0.03 Lifting Equipment

Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032) for further details.

10.13 10.13.1

Administrative

and Operational

Duties

Person in Charge

1.

Familiar

with the suspended

2.

Satisfied

with the fitness

workbasket

3.

Satisfied

with the visibility.

4.

Check the crane and workbasket

have current valid Inspection

Certificates.

5.

Check the crane and workbasket

are registered

for workbasket

6.

Check suitability

7.

Ensure participants

and training

requirements. of the people to be work from the work basket

and approved

operations with SMEP’S Lifting Technical Authority. of wind speed for crane operations are briefed and understand

the requirements

for workbasket

operations. 8.

The Banksman

9.

Ensure that the Supervisors

is clearly identified. and Banksman

are familiar

with the workbasket

requirements and handling of workbaskets. 10.

Have verified

the competency

and experience

Page 53 of 247

of the crane operator.

operation

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

11.

AND HOISTING

Ensure communications

SMEP.EP200802258279

MANUAL

are established

REV.1.0

with all parties concerned

for the workbasket

operations. 12.

Toolbox meeting

13.

Personnel

14.

Carry out Risk Assessment

15.

Authorise

10.13.2

held with all parties involved.

are wearing the correct PPE.

and sign the work permit.

Banksman

Shall confirm to the Person in Charge the following: 1. The work basket operations requirements is understood 2. The workbasket is checked, suitable for the operation and is correctly rigged. 3. Have confirmed the personnel working from the workbasket are fit and understand the requirements; a demonstration of how to use the workbasket will be given if required. 4. Communications have been established on a dedicated radio channel. 5. 2 riggers to handle the tag l

10.13.3 Shall confirm

ines.

Crane Driver to the Person in Charge the following:

Check

1. The crane is fully operational. 2. The environmental conditions are satisfactory for safe operation for the suspended workbasket. 3. The requirements and requirements for suspended workbasket operations have been understood. 4. A full and unobstructed view of the Banksman and the area.

workbasket operating

5. Hands free communications have been established. 6. Daily crane checks have been completed and signed by the crane driver. 7. The workbasket and lifting gear are in a safe s

tate of repair before use.

8. That the crane will carry no other load than t 9. That the logbook entry will be

10.13.4

he workbasket.

made for each lift.

Riggers

Shall confirm to the Banksman

the following:

1. Have been briefed and understand the suspended workbasket requirements. 2. Familiar with handling the tag li 3. Know how to control the swing wit

nes. h the tag lines.

4. Follow instructions from the Banksman.

Page 54 of 247

Check

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.13.5

Personnel

Shall confirm

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Working from a Workbasket

to the Person in Charge the following:

Check

1. Have been briefed and understand the suspended workbasket requirements. 2. Agreed to the work from the suspended workbasket. 3. Are physically fit and to declare if they

suffer from Vertigo (Fear of height), etc.

4. Understand that the work is purely on voluntary basis. 5. Familiar with the method of suspended workbasket operations. 6. Observe all instructions from those in charge of the

operation.

7. Insist on being accompanied by an experienced person if working from a suspended workbasket for the first time.

10.13.6

Crane Owner’s Requirements

The owner of the crane used to suspended workbasket shall ensure that: 1.

The crane is registered Technical Authority.

and approved

2.

A logbook

to enable the crane operator

3.

This logbook

10.13.7 1.

is available

must be made available

for personnel

for inspection

basket transfer

with SMEP’s Lifting

to make entries of each lift. on request.

General Precautions Moving the suspended

workbasket

shall be only underpowered

conditions

in a slow

controlled, cautious manner. 2.

The load line hoist drum shall have controlled apply in neutral position.

3.

The total weight including

load lowering.

Free fall is not allowed

suspended

workbasket,

Automatic

brake shall

. rigging and occupants

shall not

exceed 50% of the cranes rated capacity for the radius and configuration used. 4.

Rigging

used for personnel

hoisting

must not be used for any other purpose and shall

be kept apart from other rigging and clearly identified as only to be used for personnel hoisting. 5.

The rigging must be capable

of handling

10 times the maximum intended

Page 55 of 247

load.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.13.8

AND HOISTING

SMEP.EP200802258279

MANUAL

Carrier Pre-use Inspection

REV.1.0

Check

Longer leg Slings must be fitted with a high visibility cover

The shackle type to be used is the bow or anchor type fitted with split pins, that is, bolt, nut and s plit-pin.

NOTE:

10.13.9 1.

Slings are correctly attached and in good order

CHECK SAFETY HARNESS ATTACHMENT POINTS ARE SECURE.

Trial Lifts A trial lift with the unoccupied

work basket carrier loaded with ballast

the intended load, including personnel, shall be undertaken at the start the suspended work basket will be used. 2.

After the trial lift and just prior to hoisting

the personnel,

shall be hoisted a few centimetres and inspected

Page 56 of 247

by the PIC.

at 1.25 times of each day

the workbasket

and rigging

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

11.0 Use of Mobile 11.1 It is not

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Cranes on Marine Vessels

Purpose Shell Malaysia Exploration and P

roduction (SMEP) pra

ctice to allow the use

of mobile

cranes on marine vessels, however their use may be allowed when the requirements of this standard are strictly adhered to. This section provides the requirements which shall be followed when using a

mobile crane on a

marine vessel. A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-G01

(section

4 page 15)

11.2

Scope

The scope of this section c

overs the use of

mobile cranes mounted

on marine vessels. These

types of arrangements shall be considered as a floating crane. The pos marine vessel affects the trim and stability of t

ition of the crane on the

he combination, and this has to be taken into

account. This section specifies the minimum requirements for the marine vessels listed the list is not exhaustive.

below, however,

It is the duty of the Contract Holder to ensure t

hat any marine vessel

w he r e l i f t i ng o pe r a t i o ns a r e u nde r t ak e n o f f s ho r e , has e qui pm e nt w hi ch co m pl i e s w i t h t he marine vessels classification society’s rules and this manual. Examples of marine vessels where this section will 1.

Pipe laying ships and barges.

2.

Crane barges,

3.

Dredgers,

apply:

work barges

using cranes with clam shells or buckets.

Examples of marine vessels where this section 1.

Supply/Anchorhandling

2.

Shuttle

3.

Dredgers,

4.

Survey vessels

5.

Jack up rigs

6.

Drilling

vessels

w i l l n o t a p p l:y

and stand-by

vessels

tankers except those fitted with cranes using clam shells or buckets

Vessel

11.3 Requirements 11.3.1

Crane Suitability

It shall be noted that mobile cranes are particularly sensitive t

o external influences such as

environmental effects, vessel movements, and dynamic loading. There are several types of mobile cranes, initially designed for land-based operations, which can be considered for lifting operations offshore. Not all however are equally suitable, e.g., a wheel-mounted crane, will

Page 57 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

not be suitable, because of tyre floatation effects and s

REV.1.0

horter wheelbase. It is not as st

able as

a tracked/crawler crane for the same duty and/or operating conditions. The suitability of a mobile crane for use on a marine vessel shall therefore be carefully appraised according to service requirements, type of marine vessel

and operational requirements.

Mobile cranes require to be certified in accordance with the latest revision of IMP 0.03

Lifting

Equipment, SMEP.EP72.ST.0032. It shall be noted that the certification and load-testing of t

he

mobile crane, shall include verification that tie downs, supports, ballast counterweight and load radius configuration conform to the crane manufactures or an authority experienced in crane design and stability of craft specifications. Certification and load-testing of the

mobile

crane must be undertaken after the crane has been mounted on the marine vessel and prior to utilisation in Malaysia; the certification and load-testing of the

mobile crane requires to be

undertaken by a third party surveyor from a classification society and witnessed by SMEP’s Lifting Technical Authority. Subsequent certification of the mobile crane shall be at the ti

me intervals detailed in IMP 0.03

Lifting Equipment, SMEP.EP72.ST.0032, witnessing of these certifications by SMEP’s Lifting Technical Authority is not required. .

11.3.2

Types of Mobile Cranes

Mobile cranes that feature all hydraulic power transmission, integrated control systems, enclosed gear drives and brakes open gear drives and open

are preferred opposed to mechanically driven cranes using brakes/clutches.

TABLE 1 outlines in general terms, the prospective suitability of

various types of mobile cranes

for use on barges.

TABLE 1 Monohull. TYPE OF MOBILE CRANE & MODE OF USE

Sea lifts

W he e l m o u nt - f r e e l i f t i ng/ t r a v e l l i ng o n t y r e s Whe e l m o u nt - f r e e o n o ut r i g ge r s Whe e l m o u nt - o ut r i g ge r s t i e d- do w n W he e l m o u nt - f i x e d cha s s i s

Inboard

NP NP

NP

POSS

POSS

YES

Crawler crane - free lifting / travelling on tracks

NP

POSS

YES POSS

Crawler crane - tied-down

YES

YES

Crawler crane - fixed chassis

YES

YES

NP

Not Permitted

YE S

P r e f e r r e d o pt i o n

POSS

Possible

risks are as low

option,

where a risk assessment has been performed that shows that the

as reasonably practicab

le (ALARP).

Page 58 of 247

lifts

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

The risk assessment shall be appraised by the contractor and the executing department and submitted to SMEP’s HSE department and Lifting Technical Authority for review. Other factors for consideration when selecting mobile cranes for use offshore are as follows: •

Cranes, which operate with outriggers deployed, shall have the facility to withstand any high pressure generated in

the outrigger's hydraulic system, arising from dynamic

lifting operations. •

Booms shall have adequate torsional stiffness, rigidity and lateral stability

for the

service specified. Box section booms of the type used on ram luffing/telescoping cranes are not considered suitable. •

Mobile cranes fixed, tied-down or pedestal mounted shall still

be considered as mobile

cranes. NOTE:

ALL OTHER TYPES OF MOBILE CRANES ON MARINE VESSELS, WHICH ARE NOT INCLUDED IN THE CLASSIFICATION SOCIETY REGISTER OF LIFTING GEAR, OR ARE NOT COVERED BY THIS STANDARD, WILL BE CONSIDERED BY SMEP'S LIFTING TECHNICAL AUTHORITY ON A CASE-BY-CASE BASIS. THEY SHALL BE STRICTLY APPRAISED IN ACCORDANCE WITH THIS SECTION.

11.3.3

Crane Capacity

The capacity charts displayed in the operators cab shall clearly show the maximum crane list the crane can safely operate at. The charts will

reflect the type of crane mounting and

operating conditions i.e. static or dynamic lifting. •

Capacity charts supplied for a fixed mobile crane shall be based on structural strength.

• Capacity charts for a deck-mounted crane shall be based on stability (tipping). It is preferable to have crane capacity charts based on allowable crane list supplied by the

crane manufacturer. W he r e t hi s i s no t po s s i bl e , a n a ut ho r i t y e x pe r i e nce d i n cr a ne de s i g n a nd s t a bi l i t y o f cr a f t s ha l l provide capacity charts and the maximum amount of crane list the charts are applicable for. The capacity charts shall be confirmed and approved by the marine vessel’s Classification Society, Naval Architect or Warranty Surveyor. The crane’s load indicator shall be recalibrated to reflect the crane’s reduced capacity charts.

11.3.4

Crane Stability

for Deck Mounted Cranes

The minimum stability margin for a deck-mounted crane shall be 1.33 X the safe working load. Stability testing of the deck-mounted crane shall be carried out if the crane has from its land-based duties to achieve a stability margin of 33%.

Page 59 of 247

been de-rated

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

11.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Weather Criteria and Mobi le Offshore Unit (MOU) Stability

11.4.1

Weather Criteria And Mobile Offshore Unit Stability

The weather criteria and maximum MOU movement for all mobile cranes on marine vessel operations shall be as follows: Mean wind Velocity

:

10 m/s measured

Significant

:

ofpitch not ofmore than (on 2 metres, the vessel. site forecast data)

wave height

Maximum list

:

at 10 metres above the sea and a 3° roll 2 deg conditions NOTand weather

as advised by the crane manufacturer or the authority experienced in crane design and stability of craft.

The master of the marine vessel or attending marine vessel

shall demonstrate that the above

w e a t he r cr i t e r i a a r e m e t a t a l l t i m e s du r i ng l i f t i ng o pe r a t i o ns . T he co nt r a ct o r s ha l l l i a i s e w i t h the CSR on site who in turn, will liaise with the SMEP Marine Department of

to confirm the sea

state values. In all cases when the above sea s

tate values are exceeded the mobile crane shall have the

boom lowered onto the boom rest. Crane activities can only resume when the sea

states fall

below the above stated values.

11.5

Mobile Cranes Ti ed-Down, Free

11.5.1

Lifting and Travell ing Wi th Load

Vessel deck Strength

The vessel’s Classification Society or Naval Architect shall verify that the vessel’s deck is strong enough, under all operating conditions and the cranes operating area for the use of the proposed mobile crane. The deck structure of the marine vessel and any mats/bearers used, shall be adequate to support all forces generated by the operation and test loading of t

he crane including:

The maximum force that would cause the crane to tip. a.

Tractive

b.

Braking forces when arresting hoist and boom.

c.

Dynamic forces including

d.

Forces generated

e.

Forces induced by any motion of the barge.

11.5.2

forces i.e., forces to propel/travel travelling

the crane. and/or slewing

and, decelerating

the load

any forces arising from offleads/sideleads

by steering

and spragging

of the crane.

Mobile cranes tied-down

Mobile crane’s operating on a marine vessel, require to be tied-down or fixed at locations on the deck. The location of the t

dedicated

ie-down points on the crane/marine vessel and, the

method of fixing via welding, bolting, turnbuckles etc., shall be agreed between the marine v e s s e l ’ s C l a s s i f i c a t i o n S o ci e t y o r N a v al A r chi t e ct a nd t he cr a ne m a nu f a ct u r e r / s uppl i e r . T he

Page 60 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

crane supplier shall verify that the method used to fasten

or restrain the crane to the deck is

strong enough, under all operating conditions to prevent the crane from breaking off the deck or moving on the marine vessel. The supplier shall provide a critical assessment of the

strength and failure mode sequence of

the tie-down points and of the crane’s primary load path elements including as boom, A-frame, bedplate, car body, chassis,

appropriate;

outriggers, hydraulic rams (luffing and

outriggers), slew bearing and fasteners and all primary load carrying pins. The calculations of all forces transmitted to the marine vessel’s

structure and the sequence of failure report in

conjunction with the lift programme that the mobile crane is intended to be assessed and approved by the marine vessel’s Classification Society, Naval Architect or a SMEP recognised warranty surveyor. The crane supplier shall

used for, shall be

provide copies of the approved

calculations and the sequence of failure report to SMEP’s Lifting Technical Authority for review. A l l c r a ne t i e -do w n w e l ds t o be s ubj e ct ed t o 1 00 % v o l um e t r i c a nd s ur f ac e i ns pe ct i o n m e t hod s prior to utilisation in Malaysia. The crane tie-down welds shall

be subject to 100% visual inspection every six months and 100% volumetric and surface inspection annually.

11.5.3

Mobile cranes free lifting

Because of the particularly large and random motions of monohull marine vessel’s arising from w av e ac t i o n, t he us e o f m o bi l e cr a ne s f o r f r e e l i f t i ng s ha l l no t be SM E P ’ s pr e f e r r e d o pt i o n. However, where cranes are required to free lift, the crane must work on a timbered area and have travel restrained by side constraints and end stops. When not working, the crane chassis is required to be anchored with tie-downs to the deck and the boom lowered on

to a boom rest.

W he r e c r a ne s a r e r e qu i r e d t o f r e e l i f t , pa r t i cul a r l y w he n t he m o t i o n o f t he m a r i ne v e ss el ca n cause the load to pendulum and adversely affect the stability of

the crane.

A risk assessment

shall be performed that shows that the risks are as low as reasonably practicable (ALARP). SMEP's Lifting Technical Authority shall carefully consider free lifting on a case-by-case basis,

only after approval has been granted by SMEP’s Lifting Technical Authority shall work commence. The supplier shall provide a critical assessment of the cranes stability, based

on the

w e a t he r cr i t e r i a a nd m a x i m u m M O U m ov e m e nt de t a i l e d i n P ar a 1 0 . 5 . T he ca l c ul at i o ns o f al l forces transmitted to the marine vessel’s structure and the critical assessment, shall be

assessed

and approved by the marine vessel’s Classification Society, Naval Architect or a SMEP recognised warranty surveyor. The crane supplier shall provide copies of the approved calculations and the critical assessment report to SMEP’s Lifting Technical Authority for review. The supplier shall ensure that the provision of any mats, bearers et

c. used to spread these

forces are positively and effectively secured to the deck of the marine vessel. used to carry the load across the deck of the barge shall not

any de-stabilising effects under any operating condition and, under any forces arising from Section 10.6.1 a), b), c), d), e) and f).

11.5.4

Mobile cranes travelling

Any mats/bearers

deviate, move, spread or cause

with load

However, where cranes are required to travel with the load, they must fully meet the requirements of 10.6.3 and be shown to be ALARP.

Page 61 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

SMEP's Lifting Technical Authority shall carefully consider cranes travelling with load on a case-by-case basis, only after approval has been granted by SMEP’s Lifting Technical Authority shall work commence. On wheel mounted cranes, the effects of tyre f

loatation will add to the pendulum problem.

W he e l m o u nt e d cr a ne s s ha l l no t be co ns i de r e d s ui t abl e and a r e t he r e f o r e no t pe r m i t t ed. ( r e f e r table 1).

11.5.5

Mobile cranes used for basket transfer

Mobile cranes operating on marine vessels shall

11.5.6

N O T be used for the transfer of personnel.

Procedures

The contractor shall provide a procedure for the safe use of the mobile crane on t

he marine

v e s s e l . T he pr o ce dur e s ha l l f u l l y c om pl y w i t h t hi s s t a nda r d a nd s ha l l be f o r w ar de d t o S M E P ’ s Lifting Technical Authority for review and approval.

11.6 Documentation A l l r e c o r ds s ha l l be i n a cc o r da nc e w i t h I M P 0 . 0 3 L i f t i ng a nd E qu i pm e nt I ns pe ct i on a nd Maintenance Philosophy (SMEP.EP72.ST.0032)

11.7 11.7.1

Periodic Checks General

The Chief engineer shall ensure that the checks given in

10.8.2 to 10.8.3 have been carried

out. NOTE. It is possible the crane operator could be authorised to carry out periodic checks, to the extent that he may be considered competent.

11.7.2

Crane Pre-start

Checks

Carry out the following pre-start checks: 1.

Carry out pre-start

checks following

the Manufacturer’s

(as a minimum) a check of oil, coolant and fuel. If the

checklist.

This must include

crane engine requires refuelling

refer to Para 13.11.7. Walk round the crane and the crane access ways, visually checking for any faulty conditions or abnormalities. The checks must include audible w ar ni ng dev i ce s , al l s a f e t y l i m i t s a nd c ut o ut s , bo o m , ho o k bl o ck s , s he a v es , w i r e r o pe s and pendants (including spooling of wire rope on to the drums, rope terminations and any anchorage points), cab, control levers, slew motors, pinions and brakes. 2.

Check that the rated capacity test is carried out.

indicator

3.

Check that there are no obstructions

4.

Condition

is set for it’s correct duty and that the daily

in the travel of the crane.

of tie downs.

Page 62 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

5.

AND HOISTING

If the crane cannot operate,

SMEP.EP200802258279

MANUAL

REV.1.0

post a “DO NOT OPERATE”

sign in a prominent

position

at the crane’s controls and if necessary, in the machinery/engine room. 6.

Any faulty condition

7.

All acceptable

11.7.3

shall be reported.

conditions

Reporting

shall be recorded.

of defects and incidents

The Person in Chargeshall ensure the CSR and the project engineer are immediately notified the following: 1.

Any defects

2.

Defects

found during daily or weekly checks.

3.

Incidents

4.

Shock loads, however

5.

Dangerous

found at any other time. or accidents,

occurrences

however

slight

they occur. or reportable

accidents.

11.8 Maintenance 11.8.1

General

Provision shall be made to ensure that throughout its use the crane, tie-downs and other equipment used in the lifting operation are maintained in a satisfactory condition. The appointed person shall be satisfied that adequate

information, e.g. manufacturer's

instructions, are available and that the maintenance is carried out by trained personnel who have adequate knowledge of the correct procedures. The frequency and extent of such maintenance shall take account of all factors that affect the crane in

11.8.2

carrying out its work.

Planned maintenance

To ensure safe and satisfactory operation of the crane and workbasket, a properly planned maintenance system shall be established and used. Refer t

o IMP 0.03 Lifting Equipment

Inspection and Maintenance Philosophy (SMEP.EP72.ST.0032) for further details.

Page 63 of 247

of

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

12

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fork Lift Trucks

12.1

General

Forklift trucks, in a range of different capacities, are used for handling goods in SMEP w o r k s i t es . Forklift trucks must be equipped with a protection device that protects the operator in case of rollover. The wearing of the seat belt is

obligatory. A bright orange revolving light shall be

installed and must operate automatically while the forklift truck is in use. acoustic reversing drive alarm shall be installed.

An automatic

Only properly trained and certified people are allowed to operate forklift trucks within SMEP w o r k s i t es . A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-G01

(section

9 page 20)

12.2 Pre-Use A t t he s t ar t o f e v e r y s hi ft i t i s t he f o r k l i f t o pe r a t o r ’ s dut y t o c ar r y o ut a v i s ua l che c k o n t he truck to ensure it is in a safe condition. As

12.2.1

a minimum the following checks shall be made:

Start vehicle inspection

1.

Overhead

2.

All hydraulic

guard for security.

3.

Mast assembly

4.

Lift chains and rollers

5.

Forks, ensure they are not bent or damaged,

6.

Condition

rams and cylinders

for wear and damaged links, ensure anchors are secure. lateral

locks are present

of the wheels and tyres.

7.

Check fuel level and fuel gauge.

8.

Check seat belt condition

9.

Check the engine oil level.

10.

Check the engine coolant level.

11.

Check the transmission

12.

Check the hydraulic

13.

Check the battery

12.2.2

and hoses for leaks.

for wear.

and operation,

including

fluid level. fluid level.

condition.

Ignition ON checks

Check/Test the standard equipment: 1.

Front, tail, and brake lights.

2.

Fuel gauge (if diesel).

Page 64 of 247

anchorages.

and working.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

3.

Rated Capacity

4.

Amber warning light.

5.

Windshield

6.

Acoustic

12.2.3 1.

2.

Indicator

SMEP.EP200802258279

MANUAL

REV.1.0

(if fitted).

wiper, if fitted. reversing

alarm.

Engine Running Checks Check the gauges. a.

Oil pressure

b.

Ammeter

gauge.

c.

Hour meter.

d.

Water temperature

indicator

lamp.

gauge.

Steering

3.

Brakes

4.

Horn

5.

Lights

6.

Check the operation

12.2.4

of any load-handling

attachments,

rotator

etc.

Pre-use checks for forklift trucks not in use for an extended period of time

In cases where a forklift truck is not used for an e

xtended period of time the user shall ensure

that the person in charge specifies a special programme of pre-use checks and in-service inspections and thorough examination before it is used. The extent

and thoroughness of this

programme depends not only on the length of the period that but also on the location of the fork l

the fork lift truck was out of use

ift truck during this period. Forklift truck’s standing under

cover or inside a workshop might require very little extra inspection. Forklift truck’s that have been out of use in the open and t

herefore exposed to the weather and atmospheric pollution,

etc. might require an extensive appraisal to ensure fitness for work. The programme of pre-use checks and in-service inspections must contain, as a minimum, the following checks: 1.

Any checks that are recommended

in the manufacturers

instructions

for the forklift

truck. 2.

Checking that there is

3.

Checking that there is

all hoist chains for signs of corrosion/degradation

and damage and ensuring

thorough lubrication. all control

linkage for evidence

of seizure

or partial

seizure and ensuring

correct lubrication.

4.

Checking

for correct functioning

5.

Checking

hoses, seals or other components

of all the safety devices.

6.

Checking

for corrosion

on the structure,

7.

Checking

for structural

integrity,

for evidence

access,

for example

Page 65 of 247

control

of deterioration. linkages

etc.

cracks, dents, missing

components.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

8.

Testing

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

of every motion without load, each motion individually

at first then by

combination of two or more motions simultaneously as appropriate, and then repeating the test with a load.

12.2.5

Documents

The following documents must be present on the forklift t 1.

The current certificate

2.

The safe working load chart.

12.2.6

Hazardous

ruck:

of examination.

Zone Requirements

A ny f o r k l i f t t r uc k t hat i s r e qui r e d t o be o pe r a t e d i n a z o ne 1 or z o ne 2 a r e a s m us t f ul l y co m pl y w i t h a nd be c er t i f i e d t o t he H a z a r do us Z o ne r e qui r e m e nt s .

12.3 Operations Personnel must not operate forklift trucks unless they comply with the competency standards state d i n Ap pendix 1 of Lifti ng E quipmen t M anageme nt Syste m, EP 200803208668 and are specifically authorised to do so. Forklift truck operators shall wear a high visibility vest to aid visibility at any time when they leave the

both while driving and

operation position.

Forklift truck operators must: 1.

Not carry passengers.

2.

Not allow pedestrians

3.

Not drive in a direction stacking

to walk under the load. where visibility

4.

Not attempt

5.

Avoid fast accelerating,

and dismantling

6.

Be cautious

7.

Take care when operating

8.

Obey traffic regulations

9.

Operators

is blocked. stacks on inclines.

sharp braking or fast turning.

when travelling

on slopes,

uneven or pot-holed

in the vicinity

of pedestrians

surfaces.

or other vehicles.

must be aware of hazards in and at the perimeter

of their areas of

operation.

12.4

Capacity

Capacities of forklift trucks are

rated by the manufacturer and under no

these capacities be exceeded. The capacity is defined by a

circumstances must

given weight with the centre of

gravity at a longitudinal distance from the face of the forks. It

is stated as a maximum weight

at a maximum load centre. A forklift truck with a rated load of

3000kgs at 500mm centres will

be able to carry only 2500kgs at 600mm load centres. Rated weight x Rated distance New Distance

=

3000 x 500 600

Page 66 of 247

= 2500kgs

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

13

Mechanical Handling Equipment

13.1

General Requirements

This section establishes minimum standards for the design

and operation of mechanical

handling equipment.

13.2

Aerial Platforms

This section applies to those pl atforms, Vehicle Mounted Elevating and Rotating Aerial Devices, Manually Propelled Elevating Aerial Platforms, Boom Supported Elevating Work Platforms, and Self-Propelled Elevating Work Platforms. A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-G01

(section

10 page 22)

13.3

Design Criteria - General

The design, maintenance and operation of this equipment shall comply with an

international

standard or manufacturer's association rules.

13.3.1

Identification

of Mobile Aerial Platforms

The identification and rated load/applicable capacity ratings shall be clearly marked on the mobile aerial platform.

13.3.2

Pre-Use Operational

Checks

These inspections shall be performed each day the mobile aerial platform is

used and shall

include the following: 1.

Check safety devices

2.

Check operating

3.

Inspect

for defects

for malfunction.

and control

mechanisms

for proper function.

such as cracked welds, damaged control

cables,

and loose

cable/wire connections. 4.

Inspect

hydraulic

or pneumatic

5.

Inspect

electrical

equipment

systems

for observable

for signs of malfunction,

deterioration

or leakage.

signs of deterioration,

and dust

and moisture accumulation. 6.

Inspect chains or wire rope for wear or distortion.

7.

Inspect

mechanical

parts for any signs of wear, cracks, or distortion

such as pins,

bearings, shafts, gears, couplings, rollers and locking devices. 8.

Hydraulic

system for proper oil level.

9.

Hydraulic

and pneumatic

cylinders

and holding

valves for malfunction

damage. 10.

Condition

and tightness

of bolts and other fasteners.

Page 67 of 247

and visible

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

of controls

ratings,

REV.1.0

11.

Legible

and proper markings

12.

Legibly

and clearly marked with an unique identification

and instructions. number, date of inspection,

next inspection date, SWL.

13.3.3

Operational

Use.

Mobile aerial platforms shall be operated according to this section and the

manufacturers'

recommendations. The following practices shall be followed for mobile aerial platform operations: 1. Determine

that the proposed

mobile aerial platform

operation

is the desired

operation

after comparing hazards, productivity, and manpower requirements associated with other methods of access. 2.

Before each use, the operator

understands

the manufacturer's

operating

instructions

and safety rules, has been trained and has read and understood all decals

and

w ar ni ngs o n t he e qui pm e nt . 3.

Before each use, the operator

shall perform a pre-operational

check to demonstrate

operational readiness, including all limit switches and outrigger drift switches, if applicable, but excluding the tilt alarm/shutoff. If controls do not operate properly the operator is responsible for notifying the PIC. Repairs and adjustments shall be

made

before operations begin. The operator shall adhere to all decals on the 4.

Personnel

must not operate

aerial platforms

controls.

unless they fully comply with the

competency standards stated in Appendix 1 of the Lifting Equipment Management System EP200803208668. 5.

Before each use, the operator shall survey the area for applicable overhead obstructions and high-voltage conductors, debris, bumps and loose

hazards such as

obstructions, drop-offs and holes, ditches, soft earth, obstructed path of travel, unstable footing, and other possible hazardous conditions. 6.

Personnel a.

must: Keep all parts of the body, tools, and equipment

inside the work platform

periphery during raising, lowering, and travelling operations. b.

Hold onto a moving platform

c.

Consideration

using both hands.

must be given to prevailing

environmental

conditions

(e.g.,

w i nd, r ai n, l i g ht ni ng, s no w , e t c ) , as w el l a s as pe ct s o f t he de v i ce ( e . g . , s a i l area) before commencing operations.

NOTE IT IS A REQUIEMENT THAT ALL ACCESS PLATFORMS WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN CIRCUMSTANCE. 7.

The operator

shall establish

8.

The platform

is clearly

appropriate

safety zones before initiating

9.

The platform

shall not be loaded beyond its rated load (capacity).

marked with the number persons it is designed

Page 68 of 247

EVERY operations.

to carry.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.

The operator

AND HOISTING

SMEP.EP200802258279

MANUAL

shall ensure the equipment

REV.1.0

is within inspection

examination of the periodic re-certification tags 11.

Operator

discipline

and testing

intervals

by

and/or documentation.

shall be maintained

at all times. Personnel

shall keep all parts of

the body, tools, and equipment inside the work platform periphery during raising, lowering, and travelling operations. 12.

The use of the mobile aerial platform

to move ‘heavy’

materials

is not allowed;

materials shall not project outside the workbasket. 13.

Fall protection is required at all times for personnel using mobile aerial platforms a lanyard attached to a dedicated lanyard anchorage point. Attach only one (1)

14.

Tools and other objects

with

lanyard per lanyard anchorage point. shall be carried in canvas bags or by other methods

both hands and do not present a snagging hazard. Alternate methods of

that free

tool delivery

beside mobile aerial platforms shall be investigated. 15.

Stow the boom and shut off all power before leaving

16.

When two or more persons are on the platform,

machine

the operator

shall be responsible

for

all machine operations. 17.

Do not place boom or platform

against

any structure

to steady the platform

or to

support the structure. 18.

Keep both feet firmly positioned

on the platform

floor at all times. Never use ladders,

boxes, steps, planks, or similar items on platform to 19.

When performing

welding

provide additional reach.

or metal cutting operations,

precautions

shall be taken to

protect the chassis from direct exposure to weld and metal cutting spatter. 20.

Do not refuel the machine with the engine running.

21.

Free hanging

22.

The mobile aerial platform

23.

Persons younger than 18 years are not allowed

24.

Outdoor mobile aerial platform

loads shall not be lifted. shall not be used to exert a sideways

operations

shall not commence

37km/hr steady state or if gusts exceed 46 km/hr or manufacturer . Consideration shall also be given to

25.

force.

in the workbasket. if winds are above

as recommended by the

weather conditions such as

lightning, heavy rain etc before

commencing operations.

The requirements

apply to all uses of mobile aerial platforms;

of this section

e.g.,

movement for storage/repositioning and use of the platform close to ground level. 26.

Never allow personnel

in the platform

while towing,

lifting,

designed. 27.

Never use the boom assembly

to enter or leave the platform.

Page 69 of 247

or hauling,

unless so

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

13.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Hand trucks

Hand trucks are for moving loads over short distances (typically less than 100m), and are specially designed for lifting and moving packages or pallets e.g. hand pallet trucks. In the latter case the facility to jack up the truck may be incorporated. Hand pallet trucks are suitable for loads up to 3000kg.

13.4.1

General Requirements

1.

Hand pallet trucks must be clearly marked with an unique identification number, date of inspection, next inspection date, SWL and have an in-date certificate of inspection

2.

Hand trucks must not be used on sloping

from a third party surveyor. steel surfaces

such as ramps and particularly

not on long inclines (maximum recommended gradient 1:15). If there is no alternative, consideration shall be given to using trucks fitted with brakes. 3.

Hand trucks must not be used on uneven or soft surfaces.

Such surfaces,

e.g. cracked

concrete, distorted tarmac, sand and grassy areas, increase both the physical effort required and the risk of toppling. 4.

Special

care must be taken when using hand trucks in split level areas, e.g. loading

bays, especially where no guardrails are fitted. 5.

Hand trucks must have all their wheels in contact with the working during their use.

Users of hand trucks must report any mechanical defects to the appropriate supervisor.

Page 70 of 247

surface at all times

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

14.0 Crane Operation 14.1 Introduction This section is intended to provide fundamental safe working procedures for crane operators and associated personnel. These basic safe working procedures apply to all crane operations, regardless of crane type or classification. Most crane operations covered in this section can be classified as Routine Operations and as such will be covered by generic Lifting Plans and Risk Ass essments ( A ppe ndi x 3 ). Where Non-routine crane operations are discussed, Non-routine L ifting Plans and separate Risk Assessment measures are required refer to section 8.

14.2

Regulations

and D ocuments for safe Offshore Crane Operations

The following regulations apply directly to offshore crane operations: 1.

Lifting

Operations

2.

Shell’s

global standard

and Lifting

Equipment

on lifting

Regulations

and hoisting

(LOLER).

EP2005 – 0264-G01

(section 3 page

14). A s ne c e s s a r y , r e f e r t o section 8

of this document

and the above for guidance when planning

any lifting operations. W he n a ppl i c abl e t he r e qui r e m e nt s o f t he IM D G C o de m us t a l s o be i m pl e m e nt e d a t t he w o r k s i t e in the form of a risk assessment. Risk assessments/lift plan for ‘Routine’ l activities are being u

ifting operations can be ‘generic’ where similar

ndertaken in similar

places of work.

However, these assessments must b

e

reviewed if there is: Reason to believe that the c

ontent of the generic

‘assessment or lift plan’ is no

longer valid.

There is change in the work activity or conditions.

14.3

Lifting Team

The number of persons in the lifting team must be

determined by the risk assessment/lift plan

and be appropriate to ensure the safe operation of the crane at a

workplace, especially in

relation to minimising the risk of collision between the contacting other structures, overhead power lines or The risk assessment/ lift plan shall

crane and other plant, and loads workers.

consider the size and complexity of the lifts t

o be performed

w he n de t er m i ni ng t he nu m be r o f ope r a t o r s t o w or k t o ge t he r i n t he t e am . Crane lifting operations shall in all instances consist of

a team of minimum three people, the

crane operator, the rigger/slinger and the banksman. The duties of each are outlined in Para’s. 14.4 to 13.7.

14.4

Crane Operator

In appointing an individual to the position of crane operator on an Offshore Platform, t crane operator shall have been adequately trained, and has adequate experience and fully complies with the competency requirements of the Lifting Equipment Management System (LEMS) A ppe ndi x 1.

Page 71 of 247

he

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

The crane operator must be able to undertake all crane operations in a safe and

controlled

manner. A ny cr a ne o pe r a t o r i nv o l v ed i n s ub-s e a l i f t i ng o pe r a t i o ns s ha l l u nde r g o a s ui t a bl e s ub- s e a lifting familiarisation programme before commencing operations.

14.4.1

Crane Operator’s

Responsibilities

W he n a s i t u at i o n a r i s e s , o r a co ndi t i o n e x i s t s , w he r e i n t he c r ane o pe r at o r ’ s opi ni o n, t he safety of personnel, plant or equipment may be jeopardised, he must immediately suspend lifting operations until such time as control measures have been introduced to minimise or eliminate the recognised potential risk(s). W he n l i f t i ng o pe r a t i o ns ha v e be e n t e m po r ar i l y s us pe nde d du e t o i nc l e m e nt we at he r , o r i n t he case of supply vessel back loading/discharging because of the prevailing sea-state, the crane operator must resist any pressure to restart operations until in his opinion it

is safe to do so.

Operations must not re-commence until the crane operator is fully satisfied that conditions have improved to within the

safe operating parameters recommended by the

Crane Manufacturer, the

MOPO in the platform HSE case. W he r e no H S E ca s e o r MO P O e xi s t s t he w e a t he r l i m i t s f o r pl at f o r m a nd r i g s uppl y as we l l a s boat to boat lifting activities, shall be

2.5 m swell and a mean wind velocity of

12 m/s.

14.5 Rigger/Slinger The rigger/slinger is the Competent Person responsible for preparing and slinging a load in readiness for a crane lift.

He is also responsible for attaching or detaching load slings to and

from the crane hook.

14.6 Banksman The banksman is the Competent Person with sole responsibility

for directing (signalling) the

crane operator with respect to movement of the load on the

crane hook. The banksman must not

however commence load movement signals until the slinger informs him that it is

14.7

Banksman/Slinger

safe to do so.

Activities

A t t he c o m m e nce m e nt o f e ac h s hi f t a l l per s o nne l i nv o l v e d i n cr a ne o pe r at i ons w i l l be i nv o l v e d in a Toolbox Talk for all routine lift

ing operations. The person in charge will make the

allocation of duties to achieve an efficient and safe

load handling and lifting operation.

Banksman duties are as follows: 1.

It is important

that the banksman

is readily

identifiable

(by the crane operator)

from

other personnel e.g. by wearing a high visibility waistcoat. He must also have agreed wi t h t he cr a ne o pe r at o r t he m e t hod o f s i g na l l i ng t o be u s e d. 2.

The Banksman

controls

the initial

lifting

and movement

of the load, and its final

positioning on the landing area or site. The banksman will be responsible for load movements only; he will be assisted by a Slinger who will act as the load handler. A ddi t i o nal l o ad handl e r s c a n be us e d a s ne ce s s a r y t o e ns ur e t he s af e t y o f t he l i f t i ng operation.

Page 72 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

The Banksman

AND HOISTING

SMEP.EP200802258279

MANUAL

shall not become involved

REV.1.0

in handling

of the load. He must at all times

retain an overview of the lifting operation. 4.

The PIC, Banksman

and Slinger

shall discuss each lifting

programme

with the crane

operator to ensure that each understands the sequence relative to the priority of lifts. 5.

Prior to discharging

or back loading of supply vessels,

both he and the crane operator are in possession of a

the Banksman

shall ensure that

copy of the cargo manifest. The

person in charge must be consulted with regard to the sequence of lifts

and positioning

of loads 6.

The banksman

must be aware of the wind speed and direction

and be familiar

with the

capacities and parameters of the crane in use. 7.

He must check that the deck crew have checked the lifting

gear being used for

condition, that it is certified for use, is correctly colour coded and is of sufficient capacity to carry out the lift. 8.

Ensure that a cargo-handling

pennant

of 2 – 3 metres long and correct capacity

attached to the crane hook and is suitable for the partic

is

ular lift to be carried out.

the case of supply vessel operations, the pennant deployed s

In

hall under normal

circumstances be a minimum 3m long. Where, because of the crane' s limited boom length, a full-length pennant cannot be deployed, the pennant possible.

If no extension is possible, a

must be as long as is

tag line is to be fixed

just above the cran

e

hook. The crane operator and vessel's crew must exercise utmost caution. 9.

Be aware of any obstructions

10.

Be aware of potential

within the crane's radius and working

snagging

points in the vicinity

area.

of the load whilst

hoisting/lowering in restricted areas. Check to ensure that the crane's hoist rope, hook block assembly and attachments have a clear passage. 11.

Ensure that the lifting

area is suitably

12.

If a problem develops

whilst lifting

barriered

off.

or landing a load, the banksman

shall identify

escape routes for all parties involved with each lifting operation. 13.

If using hand signals,

the Banksman

shall stand in a position

where he can be clearly

seen by the crane operator and he can maintain visual contact with the l

oad, load

handler(s), and see potential crane boom collision points. 14.

When using radio communications,

the banksman

shall stand in a position

where he

can maintain visual contact with the load, load handler(s) and potential crane boom collision points. 15.

When lifting,

stop the load just clear of the deck to check balance and security

load. This will also give the c rane operator the opp hoist brake. Allowance must be made for the rise and fall of

of

ortunity to check slippag e of his the supply boat in the sea

during vessel cargo operations 16.

Make it clear to the crane operator

17.

Warn other personnel

where the load is to be placed.

in the area of the movement

over personnel.

Page 73 of 247

of the load. Do not move the load

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

18.

AND HOISTING

Keep a check on other activities

SMEP.EP200802258279

MANUAL

REV.1.0

within the crane's operating

area to avoid the

development of unforeseen hazards. 19.

When carrying

out lifts, u nder radio communication,

of the crane operator (‘blind’ lifts) ensure that the

which are out of the line of vision crane operator is at all times aware

of the load movement. 20.

During ‘blind’

lifts, the criticality

of the lifting

operation

may be such that there is a

requirement for the crane operator to acknowledge and repeat the instruction he has received over the radio. 21.

During ‘blind’

lifts which are being conducted

by a hand signalling

method and more

than one Banksman is being used to relay instructions to the crane operator, each Banksman shall stand in a position where he/she can be clearly seen

by the next

person in the chain. All signals shall be clear and precise. The Banksman at shall have a complete overview of the activity. For vessel cargo operations there must

the load

be only one banksman who maintains a clear view of the crane operator throughout.

CAUTION:

22.

WHEN CARRYING OUT BLIND LIFTS, THE USE OF MORE THAN TWO BANKSMEN MAY GIVE AN UNACCEPTABLE SIGNAL TIME DELAY.

When lifting

operations

are being conducted

barrier off the hatch area and erect sig

through hatches

to lower decks, always

ns with a contact number.

The barriers must

not be removed until the hatch has been replaced and secured. 23.

If the crane stops, be

aware it m ay well be that the crane operator

banksman's signals.

Or, if radio comm

unication is being u

has lost sight of the

sed, a third party ma

y be

transmitted on the working channel. Re-establish visual or oral contact before restarting the lifting operation. 24.

While the crane is engaged in cargo handling

operations

with a supply vessel,

the

banksman shall be available to assume control of the operation if requested to by the crane operator in the event that he lo

do so

ses sight of the supply vessel deck or an

emergency situation arises. 25.

Do not land loads on areas that are designated

26.

Do not direct the crane in a load path over live plant cooler banks etc.

27.

Do not drag trapped slings or other lifting

28.

Use lifting

equipment

specifically

designed

as ‘No Load’ areas.

equipment

from under loads.

for that purpose to remove barrels,

drums

etc. from transit carriers or containers. Always ensure the integrity of the barrel rim. The same equipment shall not be used to l

ift barrels or drums across platform areas.

Secure slinging methods must be used. 29.

Prior to either transfer

on the platform

or to a supply vessel the security

of cargo

inside containers or baskets etc must be ensured. Additionally the doors of

the

containers must be secured by cable tie (tie-wrap) or similar. 30.

Before movement

on the platform

or to a supply vessel,

checked to ensure: a.

Security

of panels.

Page 74 of 247

all units or equipment

shall be

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

31.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

b.

Security

c.

That no loose equipment,

of hatches.

d.

That all valves are shut to prevent spillage.

e.

That there are no unavoidable

tools or debris are lying on roof, framework

protrusions

etc.

liable to cause snagging.

Do not use plate clamps for the purpose of transferring

steel plate.

The use of plate

clamps is restricted to situations where plate is being removed from a racking system or is being moved short distances where the lift can be

retained just above ground or

deck level. A safer more secure method of lifting this type of shackles, or by using an appropriate slinging arrangement. 32.

Bundles of tubulars

such as drill pipe, casing and scaffold

the ‘double wrap’ slinging method applied ¼ length of the 33.

Appropriate

tubes must be slung using tubulars in from each end.

fist grips and cable ties (tie-wraps)

security of the slinging

material e.g. by applying

must also be applied to ensure the

arrangement.

34.

When guiding equipment, into or out of baskets or containers, always keep hands clear of the load. Personnel must not enter

35.

On occasions when it is necessary to double stack equipment, ensure that the integrity of lifting gear is not jeopardised. Cargo or equipment stowed on top of containers et c

36.

Do not stack cargo carrying units, tanks or equipment, unless they are specifically designed for that purpose and it is permitted by the platform or vessel .

14.8

Load Charts

during these

operations.

Fit tag lines to

to avoid entrapment baskets or containers

the load.

must be secured against movement (by wind) or collision with other equipment.

Load charts, also called rated capacity charts, identify what a crane is able to l

ift safely.

Load charts must be written in English and/or Bahasa Malaysia and use metric units. Where the crane has one main load chart, this must be fixed in t v i s i bl e l o ca t i on.

Page 75 of 247

he operator’s cabin in a clearly

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 1 Typical Offshore Pedestal

14.9

Mounted Crane

Protocol for the use of two-way radio communications

Crane operators must always observe the following: 1.

Set up call signs and adhere to them.

2.

Use the agreed call sign at all times to establish directions.

3.

In order to maintain

optimum performance

the authenticity

of commands

and to ensure user safety,

or

if the radio

antenna becomes damaged exposing the central core; the antenna must be replaced immediately.

14.10 Two-way Radio Communications - General Information The following must be understood: 1.

The radios must be intrinsically

2.

The crane operator

3.

Radio messages

safe and approved

and Banksman

must establish

communication prior to the commencement of any lift must reflect work requirements

for use on SMEP offshore a clear understanding

platforms.

and line of

ing operation. only; general

conversation

must not be

carried out over the airwaves. 4.

Always ensure that the transmission

button is fully depressed

microphone.

Page 76 of 247

before speaking

into the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

5.

AND HOISTING

SMEP.EP200802258279

MANUAL

Speak clearly at all times. Do not release

REV.1.0

the button until a few seconds after

completing your message.

14.10.1 1.

Banksman - Radio Communication To ensure no radio interference,

any banksman’s

accompanying

assistant(s)

radio must

be switched off. 2.

When a banksman

3.

crane operator. During 'blind' lifts where the load is being hoisted

moves position

he must re-establish

clear communication

or lowered

with the

for a long time the

banksman must: a.

Not keep the transmission

button in the depressed

position

for the duration

of

the lift. b.

Not give an instruction

at the commencement

of the lift and then cease

communication until the lift has almost reached its destination. c.

Give the initial

instruction

and then talk to the crane operator

metres to reassure him that the line of control of the lift is being 4.

To minimise

background

every 3 – 4

communication is still active and that

maintained.

noise and distortion

ensure that the radio microphone

is not

exposed to the wind. 5.

Ensure that the radio microphone

is not exposed

to rain.

If a plastic

offering full protection of the radio is not available, place a

carrying

case

plastic bag or a piece of

cling film around the microphone to ensure it is kept dry. 6.

Do not carry hand-held

radios in a coverall

protective holsters attached

pockets.

to the body by either

They must be carried in

shoulder lanyard or

addition to maintaining the integrity of the radio this w

waist belt.

In

ill also eliminate the danger (to

personnel below) of dropping the radio from height.

14.11 14.11.1

Pre-Use Crane Inspection Pre-requisites

On a daily basis, before starting any crane operational activities a crane operator must check: 1.

Crane operational

condition,

and if any fault conditions

have been reported

by

previous shift by checking the contents of the crane operations log. 2.

By personally

speaking

to the previous

operator

before he goes off-shift,

about any

relevant crane operating observations made that may not be in the log, 3. 4.

For any form of crane maintenance that may be in progress, or is due to start. If a dedicated banksman is not used, in order to re-establish/establish signalling protocol, with person designated as authorised banksman for the proposed crane operations.

Page 77 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

14.11.2

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Crane Access

Each time that the crane operator accesses the crane, to prevent slips, trips or

falls, the crane

operator must ensure that all access ladders, walkways, gates and hatches are: 1.

Free from obstruction.

2.

Clean and free from oils, greases

3.

All deck plates are secured and access hatches

4.

Service hoses, e.g. diesel,

5.

Warning

and solvents. are shut.

air, and water are empty/de-pressurised

signs and barriers

are posted as necessary,

and neatly stowed.

e.g. Crane Operations

Area, Do

Not Enter! 6.

14.11.3

No other personnel

are present on the crane, in its engine room, or machinery

room.

Housekeeping

Keep the crane cab, and machinery spaces in a clean and tidy condition. 1.

Check machinery space is clean and tidy. Clean up any oil spillage and remove any loose materials, e.g. tools, r ags. Ensure access routes are unobstructed.

2.

Ensure that all personal

belongings

or clothing

do not interfere with the controls of the crane durin

are stored in such a manner that they g operations.

Ensure cab door is

unobstructed. 3.

Check that the operator's

cabin windows are clean, windscreen

are in good condition and that the screen wash system i

wipers and sun visors

s full charged and functions

correctly.

14.11.4

Safety Equipment

The crane operator must carry out daily visual checks to ensure that all safety equipment such as life jacket, emergency escape equipment etc. is secure, to hand and in a serviceable condition. The crane operator (particularly when he is new to the crane) must confirm that the fi

re

extinguishes provided are of the correct type and size as specified by SMEP Shell Petroleum, are within examination certification, and that he knows how to

14.11.5

Crane Pre-start

use each of the units provided.

Checks

Carry out the following pre-start checks: 1.

Carry out pre-start

checks following

the Manufacturer’s

(as a minimum) a check of oil, coolant and fuel. If the

checklist.

This must include

crane engine requires refuelling

refer to Para 13.11.7. Walk round the crane and the crane access ways, visually checking for any faulty conditions or abnormalities. The checks must include audible w ar ni ng dev i ce s , al l s a f e t y l i m i t s a nd c ut o ut s , bo o m , ho o k bl o ck s , s he a v es , wi r e r o pe , pendants (including spooling of wire rope on to the drums, rope terminations and any anchorage points), pennants, cab, control levers, slew motors, pinions and brakes.

Page 78 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

2.

AND HOISTING

Check that the rated capacity

SMEP.EP200802258279

MANUAL

indicator

REV.1.0

is set for it’s correct duty and that the daily

test is carried out 3.

If the crane cannot operate,

post “DO NOT OPERATE”

in a prominent

position

at the

crane’s controls. 4.

Any faulty condition

5.

All acceptable

14.11.6

must be reported.

conditions

shall be recorded.

Pre-use checks for cranes not in use for an extended period of time

In cases where a crane is not used for an ext competent person specifies a special

ended period of time the user shall ensure that the programme of pre-use checks and in-service inspections

and thorough examination before it is used. The extent and depends not only on the length of

thoroughness of this programme

the period that the crane was out of use

but also on the

location of the crane during this period. Crane standing under cover or inside a workshop might require very little extra inspection. Crane that have been out of use in

the open and

therefore exposed to the weather and atmospheric pollution, etc. might require an extensive appraisal to ensure fitness

for work. The programme of pre-use checks and

in-service

inspections must contain, as a minimum, the following checks. 1.

Any checks that are recommended

2.

Checking

in the manufacturers

instructions

all ropes for signs of corrosion/degradation

for the crane

and damage and ensuring

that

there is thorough lubrication. 3.

Checking

all control

that there is

linkage for evidence

of seizure

4.

Checking

for correct functioning

5.

Checking

hoses, seals or other components

6.

Checking

for corrosion

on the structure,

for structural

integrity,

7.

Checking

8.

Testing

or partial

seizure and ensuring

correct lubrication. of all the safety devices for evidence

access,

for example

of every motion for several

control

of deterioration. linkages

etc.

cracks, dents, missing

components.

minutes without load, each motion individually

at

first then by combination of two or more motions simultaneously as appropriate, and then repeating the test with a l

14.11.7

oad.

Crane Refuelling

W he n r e f u e l l i ng t he cr a ne , cr a ne o pe r a t or s m us t co m pl y w i t h t he f o l l o w i ng m i ni m u m s a f e t y requirements: 1.

The crane engine must be stopped.

Refuelling

must not take place whilst the engine is

running. 2.

The appropriate

generic COSHH/HRA

(Control

of Substances

Hazardous

Health Risk Assessment) must be observed prior to commencement of the refuelling operation.

Page 79 of 247

to Health/

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

AND HOISTING

SMEP.EP200802258279

MANUAL

Extreme care must be taken to prevent overflow

REV.1.0

or spillage

of fuel onto the engine,

exhaust or electrical equipment.

14.11.8

Crane Start-up

Proceed as follows: 1.

Prior to start-up,

2.

Check that all crane emergency

ensure that all controls

stop buttons

are in neutral position.

3.

Carry out crane manufacturer’s

start-up

4.

When the crane power pack starts,

are correctly

reset/set.

checks.

check that all air and oil pressure

gauges are

wi t hi n m a nuf a ct ur e r ’ s s t at e d s a f e o pe r a t i ng r a ng e . A l l ow e ng i ne ( pow e r pa ck ) t o obtain operating temperature while maintaining a watch on all gauges. Stop crane immediately if any abnormality is observed. 5.

Switch on aviation

warning lights.

14.12 Crane Function Tests 14.12.1

Function Test Crane Controls

Carry out a function chec

k of all crane controls before each lifting operation.

If the crane is

manned and used continuously, a function test of the crane controls need only be carried out at the start of operations. Carry out safe function tests of hoist, boom and slew

14.12.2

systems.

Function Test Limit Switch Cut-outs

Limiting switches are used to prevent physical damage to the crane or part of t movement of the crane or part of the crane past its

he crane due to

designed range of motion.

These devices cause braking, including deceleration where

appropriate and stopping, when the

following extreme permissible positions have been reached: 1.

The highest position

2.

The extreme

3.

The end positions

of the hook (this is generally

permissible

operating

of horizontally

positions

known as ‘anti-two

of the jib (luff limiter);

block’) and

telescoping.

A t t he c o m m ence m e nt o f e a ch s hi f t , ca r r y o u t a f unc t i o n che ck o f t he bo o m m i ni m um r a di us c ut out and the hook block (main and auxiliary) over-hoist cut-outs (anti-two block’). These checks must also include, where fitted, maximum radius and maximum payout limits.

CAUTION:

ALWAYS APPROACH LIMIT CUT-OUTS SLOWLY AND WITH CAUTION SO AS TO LIMIT DYNAMIC SHOCK LOADING AS THE FUNCTION IS STOPPED BY THE CUTOUT, AND TO PREVENT DAMAGE TO CRANE STRUCTURE/EQUIPMENT IF THE CUTOUT FAILS TO OPERATE.

Limit switches must not normally be overridden, but if a cut-out override facility is fitted too must be function tested.

Page 80 of 247

this

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

1.

Exercise

AND HOISTING

SMEP.EP200802258279

MANUAL

extreme caution when function

testing

REV.1.0

an 'override'

limit switch,

See Caution

above. 2.

On completion

of the override

position and move the 3.

function

test, return the override

switch to its normal

boom/hook away from the cut-out.

Recheck the cut-out limit switch operation.

14.12.3

Rated Capacity Indicators

RCI (Automatic

Safe Load Indicators

ASLI)

Limiting and indicating devices are intended as an aid to crane operators. The devices be relied upon to replace the use of the crane’s load

-

must not

chart and operating instructions under

any circumstances. Sole reliance on these devices in place of good operating practices may cause an accident. Rated Capacity Indicators, are commonly known as the Automatic Safe Load Indicator (ASLI) and is a vital component in the safe

operation of the crane. If during a

function test a fault or abnormality is encountered in the operation of the RCI/ASLI, the crane must not be used for lifting until the reported condition has been safely cleared by the crane maintenance personnel. A r at e d ca paci t y i ndi ca t o r pr e v e nt s o v er l o a di ng o f t he cr a ne by s t o ppi ng a l l r e l ev a nt cr a ne functions when an overload is detected. Rated capacity means the maximum load that may be attached and handled by the crane, and may not include the weight of the hook block, falls of rope, slings and rigging hardware. The load to be raised must include the weight o

f all lifting appliances that are not permanently

attached to the crane. The crane’s load chart will provide guidance on any deductions that may need to be made. Prior to the commencement of any lifting operations, ensure that the rated capacity indicator is serviceable. Check as follows that: 1.

The onboard (platform)

2.

The main hoist and auxiliary

3.

Activate

the test function

off-board

condition

is selected.

hoist modes indicate

the correct number of falls.

to ensure that all visual and audible

alarms operate

correctly. 4.

Ensure that appropriate

load/radius

chart is in good condition

and visible

from the

crane operator’s seat without difficulty. 5.

As a check that the RCI is displaying known radius mark(s) (painted on the

NOTE

14.12.4

the correct radius, lower the crane hook over platform deck).

THE OVERLOAD PROTECTION REQUIREMENTS FOR OFFSHORE PEDESTAL AND MOBILE CRANES ARE DOCUMENTED IN APPENDIX 10.

Emergency

Load Release System

W he r e f i t t e d, che ck t ha t t he m anu al l y o pe r at e d E m er ge nc y L o a d R e l e a s e c anno t be inadvertently activated during normal operations. A f unc t i o n t e s t o f t he e m e r ge ncy l o a d r e l e a s e i s no t par t o f t he cr a ne o pe r at o r ’ s r o ut i ne function checks but is normally tested as part of the

third party examination.

Page 81 of 247

Shell Exploration & Production, ASIA PACIFIC

14.12.5

SMEP LIFTING

AND HOISTING

Emergency

Stop Buttons

SMEP.EP200802258279

MANUAL

REV.1.0

The emergency stop button shall be used only: 1.

During a periodic

2.

When the normal stop system fails to operate.

function

check.

3.

In the event of a dangerous

engine condition

or component

failure

occurring

during

crane operations.

14.12.6

System Checks Whilst Crane is Running

Periodically check all gauges to ensure that all pressures and temperatures remain within the manufacturer’s

designated safe

operating ra

nge.

1.

Listen for unusual engine and/or machinery

2.

Be aware of slight ‘shocks’,

Also: noises.

which could indicate

improper

spooling

of hoist ropes or

imminent equipment/machinery failure. 3.

If anything

abnormal

occurs:

a.

Stop the crane as soon as it is safe to do so, i.e. safely lower any load on the

b.

Check possible

c.

Report defects or malfunctions.

hook.

14.13

cause.

Routine Crane Operations

14.13.1

Signalling

A l l pl at f o r m cr a ne o pe r a t i ons r e qui r e a c r ane ba nk s m an. C r a ne ope r a t o r s and bank s m en m us t be familiar with the system of signalling used illustrated in

on board the Platform. Banksman signals are

A ppe ndi x 1 .

W i t h r es pe ct t o bank s m a n s i gna l l i ng, t he f o l l ow i ng m us t be s t r i ct l y a dhe r e d t o : 1.

The crane operator

must ensure that a hand signalling

diagram (which complies

signals illustrated in Appendix 1) is clearly displayed in the

to the

crane and is visible from

the crane-operating seat without difficulty. 2.

The crane operator

must only respond to hand or radio signals

given by the authorised

banksman. The crane operator must only respond to signals from another person in an emergency situation, i.e. when the 'Emergency Stop' signal is given, either visually or orally. 3.

When hand signals

are being used, visual contact with the banksman

must be

maintained. Crane movements must stop if visual contact is lost and recommence only w he n a cl e a r l i ne o f s i g ht i s r e - e s t a bl i s he d, o r t he ba nk s m a n r ev e r t s t o r a di o communication.

Page 82 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

4.

AND HOISTING

When the crane operator's

ability

SMEP.EP200802258279

MANUAL

REV.1.0

to see the banksman’s

hand signals

is impaired

by

inclement weather conditions, darkness, etc., and the lifting operation cannot be executed safely, even with radio communication, crane operations must stop. 5.

When radio communication

is used, the crane operator

must stop the lifting

operation

immediately if there is any interruption to the communication (e.g. third party transmission/interference). Crane operations must not restart

until clear communication

w i t h t he B a nk s m a n i s r e - es ta bl i s he d.

14.14

Load Handling on the Platform Deck

14.14.1

Routine Lifts

Routine platform lifts will be covered by a generic risk assess

ment and lifting plan and can be

undertaken without further procedures being required. (Refer section 8)

14.14.2

Non-routine

Lifts

For a non-routine lift, a specific risk assessment and lift

plan (specially generated by persons

w i t h r e l a t e d co m pe t e nce ) wi l l be r e qui r e d. A no n-r ou t i ne l i ft m u s t no t be unde r t a k e n unt i l t he s e documents ar

14.14.3

e in place.

(Refer

section 8

)

Platform Deck Work

Before starting lifting operations, the crane operator must assess the prevailing weather conditions, e.g. wind speed/direction and visibility. Lifting operations must not commence if environmental conditions are liable to jeopardise the safety of

the activity.

The crane must not be operated in wind speeds above the l

imit set by the manufacturer and/or

the MOPO in the platform safety case. The following instructions with respect to load movements on the pl

atform deck must be

observed and understood: 1.

While there is a shared responsibility

for the safety of each lifting

operation

(e.g.

crane operator, banksman and rigger or slinger) the banksman is in control of load lifting and manoeuvring activities. 2.

The work area must be closed off with barriers entering the work area. T

3.

To facilitate

to prevent unauthorised

he barriers may be made from red/white

safe handling

personnel

from

marking tape.

of the load attach tag lines or handling

lines to all long or

awkward lifts, e.g. casing/drill pipe bundles, completion baskets, etc. Ensure that the tag lines are secured to the load and not to

the rigging gear.

4.

If the load is hazardous check that it is segregated clear markings indicating its hazardous contents.

5.

Before a load is attached to the crane hook the crane operator must be aware of the w e i ght of t he l o a d and i t s di s t a nce ( r a di us ) f r o m t he cr a ne , a nd e ns ur e t hat t he R C I i s set to the correc

t duty.

The crane operator

from other loads and that it has

must also be con

knowledge and experience to carry out the lift.

Page 83 of 247

fident that he has the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

6.

AND HOISTING

Ensure that a cargo-handling (refer to

Para 14.42

SMEP.EP200802258279

MANUAL

REV.1.0

pennant of 2 – 3 metres long and of the correct capacity

) is attached to the crane hook and is

suitable for the particular

lift to be carried out. Where because of the crane' s l

imited boom length a full-length

pennant cannot be deployed, the pennant must be as long as 7.

Pennant’s

when used to lift pre-slung

of the sling set attached t

is possible. (

loads shall be hooked directly

o the load. i.e. no sling shall be

see fig 79

)

to the master link

attached between the

pennant hook and the master link. In general, rigging shall be kept

to a minimum,

except where required to allow connection from a deck load, in order to reduce the number of “links” between the load and the pennant 8.

The crane operator

hook.

must check with the rigger/banksman

correctly colour coded, of sufficient capacity and is

that the lifting

gear is

correctly secured and positioned

on the load, i.e. over the centre of gravity so

as to give a stable lift.

9.

Check that there are no loose tools, equipment,

10

Keep the load within the specified

etc on the load.

radius of the crane.

Do not permit load handlers

to

push or pull loads, or the crane hook, to outside the working parameters of the crane. The crane hoist rope, from boom tip to crane hook, must be vertical before a lift is started. 11.

At the commencement

of the first lift, the crane operator

must carefully

check the

operation of the hoist brake to ensure no slippage. 12

Without the prior consent of the OIM, or their delegate, a.

Unprotected

accommodation

b.

Vulnerable

plant, machinery,

loads must not be moved over:

or offices. live gas lines or similar wireline

and coil tubing

operations. NOTE:

WHERE A LOAD CANNOT BE MOVED OTHER THAN OVER WORKSHOPS, OFFICES OR SIMILAR ACCOMMODATION, PERSONNEL MUST BE TEMPORARILY EVACUATED FROM DANGER AREAS IN THE PATH OF THE LIFT.

13.

Before hoisting, path.

check that all personnel

When lifting equipment from

are clear of the area of the load and load

baskets or containers a

personnel are clear of the immediate area of the lift,

lift shall not start until all

i.e. outside of, and clear of the

basket or container. 14.

Take up sling slack to confirm that the banksman/rigger

has correctly

positioned

the

crane hook centrally over the load lifting point, adjust hook position as necessary to minimise any 'drift' of the load as it is lifted clear of the deck. 15.

As the load is lifted off the deck, monitor

the rated capacity

indicator

for possible

overload situation. 16.

During crane operations,

carry out all movements

in a controlled

operation of the crane reduces the possibility of the inherent risks involved with

17.

shock loading or stress t o the structure and/or machinery. When moving loads across the platform deck, the crane operator other activities/obstructions within the crane radius arc.

Page 84 of 247

manner.

Smooth undue

shall be aware of any

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

18.

When carrying

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

out ‘blind lifts’, m onitor the RCI for any loss or increase

of the load, which could be an indication that the l

in the weight

oad, or the load slings, have

snagged on the superstructure or on adjacent equipment. If this occurs, stop the lifting operation immediately and advise the banksman. 19.

The crane operator

must not leave the crane controls

whilst there is a load on the

hook. 20.

If weather

conditions

become adverse

during a lifting

operation,

the crane operator

must resist pressure to carry out lifts, which have now become dangerous. Suspend lifting operations until conditions improve and the lifting operation can be carried out safely. CAUTION:

NEVER WORK OR WALK UNDER A HOISTED OR SUSPENDED LOAD UNLESS IT HAS BEEN ADEQUATELY SUPPORTED FROM BELOW AND ALL CONDITIONS HAVE BEEN APPROVED BY THE PIC.

14.15 Cargo handling - supply vessel 14.15.1

work

Routine Lifts

Routine vessel cargo lifts will be covered by a generic risk assessment and

14.15.2

Non-routine

lift plan.

Lifts

For a non-routine vessel cargo lift, a separate risk assessment and

lift plan (specially

generated by persons with related competence) will be required (

See Section 8

). A non-routine

v e s s e l l i f t m us t no t be unde r t ak e n unt i l t he s e do cum e nt s ar e i n pl a ce .

14.15.3

Vessel Cargo Handling Operations

W he n ca r r y i ng o ut v e s s e l ca r go ha ndl i ng w o r k , t he f o l l o w i ng m us t be o bs e r v e d: 1.

Establish

early radio communication

with the vessel Master or where applicable

the

v e ss e l ' s de ck cr e w . O bt ai n a co py o f t he ca r go m a ni fe s t ( s ) , pr i o r t o co m m e nce m e nt o f the operation to be aware of the weights of

the cargo to be discharged/back loaded

to/from the vessel. 2.

Check load weights

to see if any loads are positioned

outside

crane load/radius

operating limits. 3.

If a load is hazardous,

check that it is segregated

from other loads in accordance

with

the IMO (International Maritime Organisation) IMDG Code (International Maritime Dangerous Goods Code),

and that it has clear markings indicating its hazardous

contents and that appropriate paper work forwarded to or from the vessel, in advance. 4.

Ensure that the pennant length provides

an adequate

safety margin for the sea state;

i.e. the pennant must be appreciably longer than the maximum wave height. Ensure that the pennant is of the 5.

correct capacity. (refer to

Prior to the commencement prevailing wind and

of cargo handling

sea-state conditions.

Para14.42 ) from/to the vessel,

If conditions are mar

confirm the ginal, for whatever

reason e.g. weight, position or sea state, discuss proposed operation with Vessel Master, and the Person in Charge (PIC). If there are any doubts, the proposed cargo

Page 85 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

transfer must be postponed until conditions improve. No cargo operations are to commence until the vessel's master verbally confirms by radio that he is satisfied wit the conditions and his ability to maintain station

h

and that the required controls such as

communications are in place. 6.

Before hoisting

loads from the vessel deck, ensure that the ship's crew have reached a

position of safety well clear of the appropriate hand

cargo handling area and have given the

signal, or verbal instru

ction, to hoist.

Similarly when back

cargo to a vessel deck, ensure that the ship's deck crew are in a

loading

position of safety,

we l l cl e a r o f t he i nt e nde d ca r g o s t o w a g e a r e a. 7.

When lowering

loads to a vessel deck, ensure enough slack is given in the pendant

slings to allow for the movement of the

and

vessel.

W he n ho i s t i ng l o a ds f r o m a m o v i ng v e s s e l de ck pa ck ed w i t h ca r go , t he c r a ne o pe r a t o r s hal l be alert for: a.

‘Snag-ups’

b.

Loads, which may still be secured to the vessel deck.

c.

Cargo that is heavier possible,

with adjacent

than the manifested

8.

Whenever

hoist/lower

9.

While engaged in vessel activities, loading being transmitted to

cargo.

avoid excessive

the crane.

do not be rushed by signals from the vessel 10

Where practicable, cargo lifts.

impacts and avert any shock

Wait for the correct

moment to make

the lift,

deck crew.

do not use maximum

Keep some boom r

weight.

loads over open water and not over the vessel deck.

boom radius (for the load) during vessel

adius (within RCI limits f

or weight of load) in

compensate for vessel ‘drift’ movement, and if the vessel

reserve, to

is unable to hold station,

abort action. 11.

If a load is immersed

in the sea for any reason,

be aware of the probable

increase

in

we i ght f r o m w at e r r e t e nt i o n. R e po r t t he i nci de nt t o t he P er s o n i n C ha r ge ( P I C ) f o r Lifting Operations so that he can check the load and/or contents for sustained following its retrieval. 12.

When moving long tubulars,

baskets

any damage

or other awkward loads, before taking the lift

ensure that tag lines are attached to assist platform/vessel deck. Check that tag lines

control and handling of the load on the are secured to the load and not the

load

rigging.

14.16 Transport of scaffolding Materials and Boards Scaffolding material and boards shall be transported in dedicated load carriers.

NOTE:

FOR ALL OFFSHORE LIFTING OPERATIONS SHACKLES SHALL BE OF THE 4 PART BOW SAFETY-ANCHOR TYPE, WITH RETAINING NUT AND SPLIT PIN. SCREW PIN SHACKLES SHALL NOT BE USED.

Page 86 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 2

SMEP.EP200802258279

MANUAL

REV.1.0

Beware of Swinging

Hooks

14.17 General Operating Instructions This section covers those areas of safe 1.

operating not specifically covered previously:

Do not engage slew parking brake or lock until the crane superstructure

has come to a

complete halt. 2.

Do not authorise

access to the crane or its superstructure

until the crane has been

brought to a complete halt and the parking brake applied. 3.

Do not use limit switches

4.

Do not use the crane to drag (fish) loads.

or cut-outs

to stop the crane boom or load line motions.

5.

Do not carry out single point lifts with one handling

pennant

hooked into the other.

This presents snagging potential. 6.

Do not, on cranes equipped

with more than one hook block, operate

the crane with a

handling pennant or other ancillary equipment attached to the stowed hook block. 7.

Except when back loading

to vessels,

lines attached to the load (not the 8.

Do not interfere/tamper

do not lift long or awkward loads without tag

slings).

with rated capacity

indicators

or other safety equipment

attached to the crane, such actions are extremely dangerous. 9.

Never allow personnel

10.

Never slew loads over or near diving operations.

11.

Do not lift loads of large surface areas, e.g. steel plates, in high wind conditions. A l w ay s a s s e s s t he e f f e ct t he w e a t he r c o ndi t i o ns co ul d ha v e o n t he be hav i o ur o f t he

12.

to ride on crane hook blocks or on loads.

load. Do not lift wire ropes, cables,

or other material/equipment

of a similar

nature, which

are not already spooled on drums provided for that purpose. An appropriate Risk A s s e s s m e nt m us t be co ndu ct e d a nd o ne o f t he f o l l o wi ng m e t ho ds a do pt e d:

Page 87 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

a.

AND HOISTING

Coil and then securely

SMEP.EP200802258279

MANUAL

REV.1.0

sling the material

using an approved

slinging

arrangement method involving at least a double wrap and bite. b.

Lift the material

c.

The lifting

in a single strand,

arrangement

provided

that:

is secured approximately

quarter to one-third

from one end by the use of a clamp or other device

distance

to prevent the lifting sling

slipping. d.

A certified

lifting

device specifically

designed

for the purpose is used.

13.

When carrying out lifts fr om areas such as the Drill Floor etc, ensure that the Banksman is correctly positioned to determine the crane boom proximity to potential

14.

Ensure that, where necessary,

collision points a Banksman

assists

the stowing

of the boom in its

cradle. 15.

Exercise

caution when lowering

a ‘light’

hook block so that the winch rope ‘payout

rate’ is not exceeded. 16.

Ensure awareness

of the operation

of the crane emergency

load release

and load

lowering equipment (if fitted). 17.

When operating

from a moving vessel,

correct a swinging cargo and stop

14.17.1

Stabilise

Ensure that at all stages of t

the crane operator

must assess his abilities

to

operations.

the Lift he lifting operation, the load remains in a stable

condition. In

general, the load may become unstable if at any time the centre of gravity of the load is not v e r t i c a l l y be ne at h t he cr ane ho o k or t he c e nt r e o f gr av i t y o f t he l o ad i s hi ghe r t ha n t he po i nt o f attachment of the slings to the l

oad or if the contents can move around (i.e. liquids in half

full

tanks).

14.17.2

Trial Lifting

W i t h a l l l i f t i ng o pe r a t i o ns the l o a d s ha l l o nl y be l i f t e d a no m i na l di s t a nce i n t he f i r s t i ns t a nce . This trial lift allows the

operator to check the load weight, balance stability and security whilst

it is in a relatively safe position. If any discrepancies are found the load can be lowered and the slinging revised. The sequence of the trial l ift and adjustments shall be repeated until the crane operator is satisfied that the load is safe

to lift.

A l l ow a nce m us t be m a de f o r t he r i s e a nd f a l l o f t he v es s e l w he n m a k i ng t he t r i al l i f t o f f s ho r e .

Page 88 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

15.0 Sub-sea Lifting and

SMEP.EP200802258279

MANUAL

REV.1.0

hoisting operations

The processes and practices in this section do not apply t

o any other operations or contractors

not involved in the sub-sea operation. The operations described will normally be conducted from Dive Support Vessels (DSV), Well servicing vessels, Multi support Vessel, which includes ROV, Diving and construction operations. Some cranes are suitable for sub-sea lifting, however not all. The crane manufacturer must be contacted for written confirmation of the crane’s suitability for sub-sea lifting before the crane is used. Normally sub-sea rated cranes have a wire rope constant tensioner or a passive/active heave compensator system installed, any other crane sub-sea systems must not be used without the express, written approval of SMEP's Lifting Technical Authority. Typical operations may include; •

Offshore installation, recovery, maintenance and repair of

•

Lifting in connection with diving or ROV operations;

15.1

sub-sea equipment;

Competence

The standards of competence required for the key roles in planning, managing and executing sub-sea lifts are to be in compliance with this document. The

contractor will demonstrate

compliance for the entire crew and divers who are involved in the lifting and hoist

ing

operations, prior to mobilisation.

15.2

Categorisation

of Lifts

A l l s ub-s e a l i f t i ng o pe r a t i o ns w i l l be cl as s i f i e d a s co m pl e x r e f e r t o Section 8.8.5

15.3

Lift Planning

A l l Su b- s e a l i ft s w i l l be e x e cut e d t o a w r i t t e n l i f t pl a n a s de t a i l e d i n Section 8.8.5

15.4

.

Management

.

of Change

The contractor’s process for management of change will have been reviewed and any issues resolved prior to m

obilisation.

When it is recognised that

a change is requ

operation that exceeds the contingencies included in the plan the

ired to a lifting

contractor’s management of

change process will be applied. It is important that contingencies are built minimise the possibility of disruption offshore which may make the safe

into lift plans to execution of the lift

more difficult.

15.5

Sub-sea lifting rules & sub-sea clarifications

The following practices are ‘deemed to comply’ practices for sub-sea activities only. Lifting operations will be undertaken by a minimum of four competent people: crane operator, banksman and two riggers. A t Se a B a ck - de ck o pe r a t i o ns Deck foreman is the banksman and controls access to the back deck. Typically two riggers will support him on the deck. Other persons are the crane operator and the PIC.

Page 89 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

The minimum manning and competence levels will be maintained as crew are rotated for breaks etc. Hand over procedures must be in

place.

Lifting Sub-sea involving divers Dive supervisor acts as the banksman and gives instructions to the crane operator. The designated diver gives instructions to the supervisor to move the load. Either or both divers can be load handlers. ROV Launch and Recovery Provided that the person operating the launch controls has direct line of sight of

the load

handler and effective communication by speech or radio and there are no other operations that may conflict and the risk assessment supports two man operation then launch and recovery of the ROV may be done by two people. The banksman controls the initial lifting of the of the line of vision of

load, lay-down of the load and lifts t

hat are out

the crane operator. The lift supervisor or PIC is responsible while a load

is in the air. Lifting Sub-sea involving Divers with or with out ROV Dive supervisor acts as the banksman and gives instructions to the crane operator. The designated diver gives instructions to the supervisor to move the load. If both ROV and divers are in the water, the coordination is done

15.6

through the dive supervisor.

Load Handling

The banksman must: ensure that he/she is easily identifi

able by wearing a high-vis waistcoat,

w hi ch i s c l e a r l y m a r k e d t o i ndi c at e t ha t he / s he i s t he ba nk s m an. W he n t he bank s m an co nt r o l s t he l i f t r e m o t e l y us i ng co m m u ni ca t i o n e qui pm e nt a nd i s o u t o f sight of the working party he does not controlled by the Dive Supervisor.

need to wear high visibility clothing. For example lifts

W he n co nt r o l i s pa s s e d be t we e n s ev e r al ba nk s m e n t he r e wi l l be a cl e a r ha ndo v e r pr o c e dur e agreed before the lift starts. This is

15.7

Competence

to be confirmed at the toolbox talk.

of Personnel

Sub-Sea contractors will demonstrate that they have a robust system of competence assurance and refresher training for all personnel involved in lifting.

15.8

Load Charts

Sub-sea capacity charts must be posted in the operators cabin and the rated capacity indicator must be programmed for sub-sea duties.

15.9

Crane Maintenance

The crane maintenance during sub-sea operations will be inline with the crane manufacturers recommendations.

Page 90 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

15.10

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Rope Maintenance

Spin resistant multistrand ropes have a characteristic of developing large numbers of internal w i r e br e ak s , l o ng be f o r e e x t e r nal s i gns o f de t e r i o r a t i o n be c o m e a ppa r e nt . This characteristic becomes even more pronounced when the rope is frequently immersed or sprayed with sea w a t e r , a s t hi s l e a ds t o s e v e r e i nt er na l f r et t i ng we a r . 1.

All sheaves

and guide rollers in contact with the moving rope must be given regular

v i s u al che ck s f o r s ur f a ce w e a r , a nd l ubr i ca t e d t o m a k e s u r e t hat t he y r un f r e e l y . T hi s operation must be carried out at appropriate intervals (generally not exceeding more than one week during sub sea operations). 2.

The rope must be maintained

in a well lubricated

grade rope lubricants (as recommended by the

condition

using appropriate

marine

rope manufacturer). The maintenance of

internal lubricant is especially important for multistrand ropes, due to the way they are constructed. 3.

A surface dressing must be applied at appropriate intervals hook, commensurate with the depth to which the hook is to be

from the winch drum to the deployed during sub-sea

lifting operations. Application of the surface dressing may be by whatever application method is convenient. 4.

In order to make sure that the inner layers of the rope remain well lubricated,

use an

effective pressure lubricator, an effective lubricator is one that will not only convey fresh lubricant to the core of the rope but will

also displace trapped water. This

generally requires high pressure application of a heavy grade of lubricant, from the w i nc h dr um t o t he ho o k , c o m m e ns u r a t e w i t h t he de pt h t o w hi ch t he ho o k w i l l be deployed. This shall be carried out at intervals not

exceeding six months. The lubricant

must be an appropriate heavy marine grade, as recommended by the manufacturer of the lubricator, and approved by the rope manufacturer.

15.11

Crane Inspection

The routine crane inspection during sub-sea lifting operations must be inline with the

crane

manufacturers recommendations.

15.12

Rope Inspection

During sub-sea lifting operations all accessible rope and associated equipment shall be checked visually

each day. Particular attention to the end

termination and the part of the rope

entering the end termination. A v i s ua l i ns pec t i o n o f t he r o pe , f r o m t he w i nc h dr um t o t he ho o k c o m m e ns ur at e w i t h t he de pt h to which the hook will be deployed, must be carried out at we

ekly intervals during sub-sea

lifting operations. At the same time, because multistrand rope tend to s

uffer internal damage,

local reductions in diameter or lay distortions shall be treated with the

utmost suspicion as they

are likely to indicate serious internal degradation. Any anomalies shall be reported immediately and lifting operations stopped. A t i nt e r v a l s no t e x ce e di ng 1 2 m o nt hs , t he r o pe s hal l be r e pl a ce d.

Page 91 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

W he n a r o pe i s no t i n s e r v i ce , co r r o s i o n ca n t a k e pl a ce , par t i cu l a r l y wi t hi n t he r o pe w her e s e a w a t e r m a y ha v e be e n t r appe d by any e x t e r na l dr e s si ng. T hi s m e a ns i t i s ne ce s s a r y t o s ubj e c t the rope to appropriate inspection and tests, before putting it back into s

ervice.

For crane ropes not in use, when the period of non-use exceeds

one month, the wire rope and

termination shall be subjected to external visual inspection to i

dentify any corrosion or damage

over the entire length of rope, including the end termination.

15.13

Crane/Rope

Records

Full records shall be kept for the crane involved in sub-sea lift

ing operations. This crane

record, shall be part of the records of the crane’s planned maintenance programme, the records shall contain details of all daily, weekly ins

pections and maintenance carried out on

the crane. Full records shall be kept for each rope involved in sub-sea lifting operations, from its

first

installation to discard. The records shall contain the following information: 1.

At installation,

details

of the installed

a.

Date, length installed

b.

Minimum

c.

Diameter,

breaking

load and certificated

construction,

2.

Confirmation

3.

A record of lubrication

4.

A record of inspections,

rope must include:

and name of rope manufacturer. test strength.

wire grade and surface treatment.

of daily and weekly inspections. (date, lubricant maintenance

used and application and testing,

a.

Results

of six monthly

b.

Details

of any length removed.

c.

Details

of the NDT, if applicable;

d.

Details

of pressure

e.

Details

of re-termination;

f.

Results

of the functional

needs to include:

inspection.

lubrication,

if applicable;

tests.

Page 92 of 247

method).

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

16

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Mobile Crane Operations

Only crane operators who have been adequately trained, and has adequate experience and fully complies with the competency requirements of the Lifting Equipment Management System (EP 200803208668) are all owed to ope rate cran es.

16.1

Documents

The following documents must be present on mobile cranes: 1.

Crane manual.

2.

The current certificate

3.

The safe working load charts in English

4.

Crane operators

5.

Registration

6.

The current certificate

7.

Mill certificates

8.

MPI reports of the Hooks / Hook blocks.

9.

Maintenance

16.2

of examination.

daily inspection

or Bahasa Malay.

log book.

document. of examination

for all lifting

equipment

belonging

to the crane.

for all ropes fitted to the crane.

records.

Load Charts

W he r e t he c r a ne ha s nu m e r o u s l o ad cha r t s ( e . g . f o r di f f e r e nt bo o m a nd f l y j i b co nf i gu r at i o ns ) , the charts must be kept in a book, folder or envelope in t

he operator’s cabin. Lifting must not

take place unless the load charts are in the crane cabin. Although the crane’s l

oad capacity

indictor system may appear to be operating correctly, the load charts must be available to v e r i f y t ha t t he cr a ne i s no t be i ng o v e r l o ade d. The lifting capacities specified on a load chart must never be

exceeded, except during testing

of the crane by the third party surveyor under controlled conditions. The lifting capacity of a crane is limited by: 1.

Structural

2.

Stability

strength

when the working radius is small; and

when the working radius is greater

The load charts on most cranes have a bold line

or shaded area dividing the chart into two

segments. The divided segments show the crane operator, which capacities are, limited by structural strength, and which are limited by stability. Ratings above the bold line

are based on

structural strength, while the ratings below the bold line are based on t crane. If a crane is overloaded in the structural area of the load chart, a structural or

he stability of the

mechanical component of the crane may fail. However, if the crane is overloaded in the stability area of the load chart, the crane may overturn. On some mobile cranes, there may be numerous load charts for differing boom and counterweight configurations. The load charts may be complex and include numerous conditions that must be complied with to ensure the crane can safely l factors that are often overlooked when reading load charts are:

Page 93 of 247

ift a load. Two important

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

1.

The need to subtract

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

the mass of the hook block and lifting

slings from the gross

capacity of the crane at the particular radius, unless otherwise noted on the load chart. For example, if the load chart states the crane can lift

20 tonnes at a given

radius, but the hook and lifting gear have a combined mass of one tonne, the l be lifted cannot be greater than 19 tonnes. T

oad to

his issue becomes critical for heavier hook

blocks and lifting gear (e.g. spreader beams). 2.

The need to subtract

the mass of the fly jib from the capacity

lifting from the main hook on the main boom with a f

of the main hook when

ly jib attached to the boom head,

unless this is allowed for and noted on the load chart. Capacities of the main boom are generally based on the fly jib being removed. If this issue is ignored, the l

16.3

ikelihood of the crane overturning can be very high.

Sitting of Cranes

1.

The ground or foundation, temporary supporting structures, packing or anchor points must be of sufficient strength and stability for t he maximum loading to be imposed.

2.

Settlement

and deflection

of ground support or structures

must also be taken into

account. 3.

Cranes must not be sited on soft or waterlogged have been taken to

4.

ground unless adequate

precautions

provide support to each wheel/outrigger.

Dynamic loads, which might arise during operations

must be estimated

and

calculations must include a 25% margin to allow for unpredictable effects. 5.

Mobile crane’s shall not be used during wind conditions

above 15 m/s or above the

crane supplier’s recommendations, whichever is the lower. A wind anemometer shall be fitted to the boom tip alternatively a hand-held anemometer can be used in the area of the lift. 6.

Sitting

of cranes on sloping

ground must be avoided.

Where necessary

be levelled using outriggers or other means to give a level and stable

the crane shall working

platform. 7.

Mobile cranes must be positioned

so that the risk of injury from collision

with other

plant is minimised. This issue is particularly important where mobile cranes are set up on public roads. Another way to minimise the risk of injury from collision with other mobile plant and vehicles is to increase the visibility

of mobile cranes. One way to

increase the visibility of a crane is to permanently mark the

crane’s outriggers with

high visibility hazard striping (i.e. ‘zebra striping’). The outrigger beams and/or hydraulic cylinders shall be marked with

the hazard striping.

The striping must:

8.

a.

Be at an angle 30-60 degrees to the horizontal;

b.

Be 40-150 mm wide; and

c.

Consist

of two contrasting

For cranes sited in flowing

colours,

black and yellow.

water careful investigation

must be made of any potential

for scouring effect. Constant checks must be made during operations to monitor the

Page 94 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

situation. The possibility of cranes being trapped by rising water must not

be

overlooked and cranes must be moved to safe position as necessary. 9.

Checks must be made to ensure that cranes are not sited above or adjacent

to

excavations or inadequately compacted ground, which are be liable to subside. 10

Particular

care must be taken when cranes are sited in the proximity

of hazards

including other cranes. 11.

Prior to the commencement

of any lifting

operations,

the temporary

closure

of roads

and access required for crane operations must be notified to all parties likely to affected by the closures. 12.

Cranes must not be operated

unless all personnel

including

be

third parties

of the public are cleared from the radius of the crane’s boom and loads

and members with a safety

margin of 5 metres. The barriers may be made from red/white marking tape. 13.

The operation

of any crane within 15 metres height or reach from the nearest

point of

contact (typically the boom, jib or cab) with live overhead electric cables or conductors is strictly prohibited. 14.

Mobile cranes must not be operated

where the operating

radius of the boom overlaps

wi t h t ha t o f ano t he r cr ane u nl e s s : a.

There is a clear over-riding

b.

There is no alternative

c.

The operators

business

sitting

and banksmen

requirement

or equipment

and

that can be used and

of both cranes are supervised

by a single

supervisor in accordance with the written lift plan. 15.

Where there is a danger of any part of the crane fouling any overhead obstruction e.g. bridges, gantries, pipe work, scaffolding, buildings or walls, the

or nearby

operator must work only under the direction of a banksman so positioned as to have a clear view of the crane and the obstruction. 16

Adequate

clearance

must be allowed

between any part of a crane and the nearest

obstruction to prevent contact with, and/or the trapping of personnel when the crane is slewed. 17.

Where it is not possible

to allow such a clearance,

no access must be allowed whilst

lifting operations are in progress.

16.4

Preparation

1.

Preparations for lifting operations recommendations and the lift plan.

must be in accordance

2.

Load indicators,

limit switches

overload

cut-outs,

with manufacturers

and all other safety devices must be

function tested before operation of a crane. 3.

Visual load/radius

indicators

and rated capacity

indicators

must be checked after

assembly, boom length change or any other factor, which might affect correct and safe operation.

Page 95 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

4.

Outriggers

AND HOISTING

must be fully extended

SMEP.EP200802258279

MANUAL

properly

REV.1.0

supported

and if required

by manufacturers

pinned in position. 5.

Jacks and outriggers

must be correctly

crane. Prior to operations, the crane

fitted with feet to provide a firm base for the must be jacked in accordance with

manufacturer's

recommendations. 6.

Counterweights

of the correct weight must be correctly

fitted prior to operation.

A ddi t i o na l co unt e r -w e i g ht i ng m u s t be f i t t e d a s ne ce s s a r y t o s ui t l o ad r e qui r e m e nt s and any boom or jib extension. 7.

On wheeled

cranes with pneumatic

are inflated to correct pressures 8.

Ensure that a pennant

tyres particular

care must be taken to ensure tyres

as recommended by the crane manufacturers.

of 2 – 3 metres long and correct capacity

attached to the crane hook and is suitable for the

(refer to Para14.43)

is

particular lift to be carried out.

W he r e be ca u s e o f t he c r a ne ' s l i m i t e d bo o m l e ngt h a f ul l - l e ngt h pe nna nt ca nno t be deployed, the pennant must be as long as is

possible.

CAUTION: NEVER WORK OR WALK UNDER A HOISTED OR SUSPENDED LOAD UNLESS IT HAS BEEN ADEQUATELY SUPPORTED FROM BELOW AND ALL CONDITIONS HAVE BEEN APPROVED BY THE PIC.

NOTE: IT IS A REQUIREMENT THAT ALL MOBILE CRANES WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE.

16.5

Lift Plans

A l l cr ane o per a t i o n s ha l l be s ui t a bl y pl a nne d as de s cr i be d i n Section 8 Before lifting operations, the person in charge (PIC) of the li

ft must ensure:

1.

The load is robust and not likely to break up, deform or become damaged during the lifting operation.

2.

The load is properly

slung and evenly balanced

using certified

loose lifting

tackle with

a SWL, adequate for the operation 3.

The lifting

gear is properly

attached

to the load and where lifting

points are used they

are designed for that lifting operation and are in good condition with appropriate certification stating the WLL and conditions.

16.6

Environmental

Conditions

Cranes must not be operated if the visibility of

the crane operator or the banksman is

significantly impaired by heavy rain, haze etc. Lifting operations must be suspended during heavy rain, except where it would be more hazardous not continuing the lift. Cranes must not be operated in darkness without adequate lighting to illuminate the crane’s lifting area.

Page 96 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

W i nd i m po s e s a ddi t i o na l s t r e s s e s o n bo t h t he c r ane a nd i t s l o a ds , pa r t i cul ar l y whe n a l o a d starts to swing. Extreme caution must be used during windy conditions and the following restrictions must apply: 1.

Lifting

of bulky objects

with large surface areas (tubulars,

steel plates etc.) must be stopped when t 2.

All lifting

16.7

operations

pipes, shipping

containers,

he wind speed reaches or exceeds 13m/s.

must stop when the wind speed exceeds 20.5 m/s.

General Operating

Cranes must not be left unattended whilst s

Instructions

uspending a load. When not in use and left

unattended, crane cabs and control compartments must be kept closed with controls or power packs locked off. Cabs and control compartments must be

locked and the vehicle

parked without obstructing

normal access. Cranes must not be used for any purpose other than for lifting in

a vertical plane. Do not use

for dragging or fishing a load. Crane booms must not be used to apply sideways force to an object. For

example, during

demolition, tree felling or pushing materials and boxes. Cranes must not be used as winches to drag materials or equipment. Cranes must not be used if they are not fully

rigged or are in a defective condition, e.g. if

outriggers do not fully extend, there are hydraulic fluid leaks or controls and safety equipment are defective. Lifting operations must be conducted cautiously without hoisting, lowering or slewing at excessive speed. Load swinging and snatch loading must be avoided. On completion of crane operations, the crane boom and hook must be properly secured before the crane operator leaves the crane. The crane boom must be left on any fitt hoist rope slackened, or pointing downwind with the boom angle lower than

ed rest, with the 45°.

A ny de f e c t o r da m a ge t o t he cr a ne o r i t s s t r uc t ur e a f f e ct i ng t he s af e t y o f t he cr a ne m us t be reported. The crane must be taken out of service immediately the defect or damage is detected and not used until it has been rectified,

and re-certified if necessary.

Page 97 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

17.0 Mult iple Crane Lifts Lifting a load with two or more cranes requires greater attention to planning and supervision, because the effects of the relative motion between on the cranes, the load and the lifting

17.1

the cranes may create additional loadings

gear in place.

Safety Measures for Multiple Crane Lifts

W he r e po s s i bl e, a v o i d ho i s t i ng a l o ad w i t h m o r e t ha n o ne cr a ne . H o we v e r , w he r e i t i s necessary to lift a load using more than one crane, the fol lowing steps must be taken: 1. The person in charge (PIC) of the lift shall be in overall control of the lift. 2.

Make an accurate

assessment

of:

a.

The share of the load that is to be carried by each crane.

b.

How the load sharing

is to be proportioned.

c.

How the proportioning

is to be maintained.

3.

Make sure the instructions to each crane operator clear, and rehearse the operation wherever possible.

4.

Use cranes of equal capacity

5.

Make sure that both cranes are aligned in the same direction type cranes in the pi

6.

Use luffing

17.2

and similar

and other persons involved

characteristics,

are

where practicable. when using non-slewing

ck-and-carry mode.

up in preference

Calculated

to luffing

down.

Share of the Load

W he r e m ul t i pl e ho i s t i ng o pe r a t i o ns a r e c ar r i e d o ut , t he f ol l o w i ng m i ni m u m ca pa ci ty requirements for each crane will apply: 1.

For two cranes—20%

greater than the calculated

2.

For three cranes—33%

3.

For four or more cranes— 50% greater

If it is not possible

greater than the calculated

share of the load. share of the load.

than the calculated

engineer must check and certify the lifting plan.

17.3

share of the load.

to comply with the minimum capacity requirements stated above, then an

Principles for Multiple Crane Lifting

The following factors are to be considered when planning for multiple crane lifts: 1.

Mass of the load.

2.

Position

3.

Mass of the lifting

4.

Safe working capacity

5.

Synchronisation

of the centre of gravity. gear. of the lifting

gear.

of crane motions.

Page 98 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

17.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Mass of the Load

Ensure the total mass of the l information is taken from a

oad and its distribution is either known or calculated. Where the technical drawing, ensure allowances are made

for manufacturing

tolerances.

17.5

Position of the Centre of Gravity

Due to the variable effect of manufacturing tolerances and rolling margins, the position of the centre of gravity may not be accurately known. Accordingly, the proportion of the load being carried by each crane may therefore be

17.6

uncertain.

Mass of the Lifting Gear

Ensure the mass of the lifting

gear and its distribution are accurately known and included as

part of the calculated load on the cranes. Where heavy or awkwardly shaped loads are handled, the deduction from the safe working loads of the cranes to lifting gear may be quite significant.

17.7

allow for the weight of the

Safe Working Capacity of the Lifting Gear

Ensure the distribution of the forces within the lif

ting gear, which will arise during the lifting

operation, is established. The lifting gear must have a s

afe working capacity margin in excess

of that needed for its proportioned load. Determine whether special lift

ing gear is required to

suit the maximum variation in distribution and direction of applied loads and forces, which may occur during multiple lifting.

17.8

Synchronisation

of Crane Motions

Minimise the variation in the direction and magnitude of forces acting on the

cranes by

synchronising the cranes’ motions. Where possible, ensure cranes of equal capacity and similar operating characteristics are used. However, in practice, there due to differences in response to the activation of

will always be

some variation

the motion controller and the setting and

efficiency of the braking system. A s i t i s unl i k e l y t ha t t he m ot i o ns o f t he cr ane s wi l l be acc ur a t e l y s y nchr o ni s e d, e ns ur e t ha t a n assessment of the effect of

variation in plumb of the hoist ropes, which may arise from

inequalities of speed, and the means for keeping such inequalities to allow for these inequalities, the lifting

a minimum, is made. To

operation must be performed at low speeds with extreme

care to ensure the hoist ropes are kept as close as

possible to vertical.

The rated capacity of a crane is calculated on the assumption that the l lowered in a vertical plane. The crane boom has limited strength in t

Page 99 of 247

oad will be raised and he lateral plane.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

18.0 Precautions when Using Mobile 18.1

Cranes

Lattice Boom Cranes

On lattice boom cranes, the top of the ext

ended boom must not be lowered to a point below the

horizontal line that passes through its boom heel pivot the angle of pull of the begins to lift.

pin. If the boom tips below this

plane,

boom luffing ropes could cause the boom to buckle before the boom

Lattice boom cranes must not be moved uphill with an unloaded boom in the near position, or operated: 1.

With the boom at an angle less than that shown on the load chart.

2.

With the boom hard against

the boom backstop

vertical

to avoid serious damage to the

structural members of the boom. Regard the boom backstop as a safety device only.

18.2

Hydraulic

Boom Cranes

W he n e x t e ndi ng t he bo o m o n hy dr a ul i cal l y o pe r a t e d cr ane s , e ns u r e t ha t t he bo o m s e ct i o ns ar e extended or retracted in accordance with the manufacturer’s recommendations. The crane must not be operated with the boom at an

angle less than that shown in

the load

chart.

18.3

Precautions

with Pick-and-Carry

Cranes

W he n m o v i ng a l o a d i n t he pi ck - a nd- ca r r y m o de , t he ba nk s m an m us t r e m ai n i n s i g ht o f t he crane operator, and not walk in the path of the crane. When t

ravelling and manoeuvring with a

load, the crane operator must ensure that: 1.

The slew brake is applied at all times other than when the slew motion is being used.

2.

Precautions

are taken on uneven road surfaces

when loaded or unloaded,

as an

undulation in the road surface may move the crane into an unstable zone. 3.

The slewing

brake or lock is applied when travelling

4.

The crane is not moved uphill with an unloaded

with a load.

boom in the near vertical

position.

A l w a y s t r av e l s l o w l y t o pr e v e nt e x ce s s i v e s w i ngi ng o f t he l o a d. T he l o ad m us t be ca r r i e d a s close to the ground as possible, and must not be

lifted higher until it is almost in

position.

W he r e po s s i bl e , a v o i d t r a v e l l i ng t he m obi l e c r a ne a cr o s s s l o pe s o r ov e r po t ho l e s , de pr e s s i o ns , soft ground etc. as these could de-stabilise the crane or load.

Page 100 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

19.0 Vehicle-Loading Cranes 19.1

General use

V e hi cl e -l o a di ng cr a ne s a r e i nt e nde d t o be m o u nt e d o n a br o a d r a ng e o f v e hi cl e s i ncl u di ng f l a t bed trucks and prime movers. When

srcinally introduced, vehicle-loading cranes were used

for loading the truck on which they were mounted. However, with the introduction of larger capacity vehicle-loading cranes, these types of cranes are also used for traditional crane operations where either: 2.

The load is lifted from the vehicle

bed to an elevated

area at a workplace

(e.g.

lifting containers from the vehicle directly to the work area); or 3.

The load is lifted both to and from locations,

remote from the vehicle

on which the

crane is mounted. 4.

While vehicle-loading

cranes may be used for the applications

level of safety provided by the lift

stated above, the

ing set-up must not be less than if a

mobile

crane was used.

19.2

Crane and Vehicle Suitability

V e hi cl e - l o a di ng c r a ne s m us t o nl y be m o unt e d o n v e hi cl e t y pe s a nd m o de l s s pe c i f i e d by t he crane manufacturer. Failure to comply with this could lead to structural failure of the crane or v e hi cl e , o r m a k e t he cr a ne co m bi na t i o n uns t a bl e . The method of mounting the crane to the vehicle must

be in accordance with the crane

manufacturer’s specifications. Any adverse effects to both the vehicle and crane are to be taken into consideration. Welding the crane to the vehicle chassis is because it can damage the chassis, and also leads to

19.3

generally unacceptable

fatigue failure of the connection.

Rated Capacity Limiters

The purpose of the rated capacity limiter is to prevent movements t moment in excess of the rated capacity, and to also permissible stresses in the structure. Refer to

19.4

Operational

hat may increase load

prevent an increase of the load radius or A ppe ndi x 1 0 for the requirements.

Issues for Vehicle-Loading

Cranes

The vehicle-loading crane must be operated in accordance with the operator’s instruction manual provided by the crane manufacturer. Additionally, the following points must be complied with: 1.

Operators

must be trained in the specific

operation

of the particular

vehicle

loading

crane. 2.

If the load is out of the operator’s

view at any stage during the lifting

3.

movement of the load must be directed by a qualified banksman. The crane may only be used with all outriggers extended manufacturer’s instructions. Where multiple positions can be the legs must be set up in compliance with the

in accordance

the

with the crane

used on outrigger legs,

manufacturer’s load chart.

Page 101 of 247

process,

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

4.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

The crane must only be used so that it is level in accordance

with the crane

manufacturer’s specifications (usually not exceeding 1º or less). 5.

Timbers

or other supporting

pads specified

provided under the outrigger feet for 6.

Hooks must be provided

by the crane manufacturer

every lift in every

with spring-loaded

must be

circumstance.

safety latches,

and must be adequately

maintained. 7.

Where it is possible

8.

w i t h an a ppr o pr i a t e s w i v e l . The crane must never be used in pick-and-carr

9.

Vehicle-loading

10.

Where provided, operation.

11.

The crane must only be used with a load suspended

The outrigger

y mode.

cranes are not to be used for lifting

is not to be used to 12.

to apply a side load to the crane hook, the hook must be provided

spring lock-outs

on the vehicle

persons.

are to be activated

vertically

during crane

from the hook. The crane

drag a load across a supporting surface.

legs shall be clearly

marked with ‘zebra striping’

Refer to 16.3 –7 for details.

Page 102 of 247

to improve visibility.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

20.0 Use of Tag Lines In certain circumstances soft lines may be used to assist items of cargo.

These are often referred

in the handling of long and/or fragile

to as tag lines.

It must be recognised that, whilst such aids may assist

operations, their use does introduce

some additional risks, as described below.

20.1

Risks

A ddi t i o nal r i s k s as s o ci a t e d w i t h t he us e of t a g l i ne s i ncl ude t he f o l l o w i ng : 1.

Potential

injuries

from dropped objects as a result of personnel

handling

cargo having

to work in closer proximity to suspended loads than would normally be the case. 2.

Potential

injuries

resulting

from personnel

handling

cargo being dragged across the

handling area, through a heavy load rotating in an uncontrolled manner and the tag line being fouled in limbs or clothing.

20.2

Make-up of Lines

1.

Make-up of lines includes

2.

Tag lines must be made up from single,

3.

Preferred

4.

The minimum diameter

5.

Apart from the knot attaching

rope materials

the following: continuous

are Polypropylene

length of rope.

or Manila.

of rope used shall be 16 mm. the line to the cargo, there must be no other joints or

knots in the line. 6.

Tag lines must be of sufficient safe position well clear of

length to allow personnel

the immediate vicinity of

handling

the load.

cargo to work in a

In this regard the

length

of the line shall be not less than one and a half (1.5) times the maximum height above the handling area at which the arrangements will be used.

20.3

In Use

W hi l s t i n u s e , pr e ca u t i o ns s ha l l be o bs e r v e d a s fo l l ow s : 1.

Tag lines are an aid to positioning

the load when landing,

and as such must only be

used when weather conditions would permit the lifting of the ite such arrangements. the use of tag lines will 2.

At all times personnel

It must not be assu

m without the use of

med that, in conditions mor

e severe than this,

allow the operation to be completed safely. handling

tag lines must work at a horizontal

load equivalent to its height above the handling area, maintaining an angle bet the line and the horizontal of not more t

distance

from the ween

han 45º.

3.

All sections of the line, including handler and the load.

slack, must be kept in front of the body, between

4.

Where two or more persons are handling

the

the same line, all must work on the same side

of the line.

Page 103 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

5.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Tag lines must be held in such a manner that they can be quickly and totally They must not be looped around wrists, or other parts of the

6.

Particular

care must be taken when using tag lines whilst wearing gloves to ensure that

the line does not foul the 7.

glove.

Tag lines must not be secured or attached equipment.

released.

body.

This includes the practice

in any manner to adjacent

of making a

“round turn” on stanc

structures

or

hions or

similar structures and surging the line to control the load. 8.

Where pre-installed lines are used, consideration shall be given to providing personnel w i t h bo a t ho o k s o r s i m i l ar e qui pm e nt t o r e t r i e v e t he l i ne s wi t ho ut hav i ng t o a ppr o a c h the dangerous area

in the vicinity of the

suspended load.

An example of such

circumstances would be when lines are attached to a load on the deck of a load being then transferred to an offshore installation.

Page 104 of 247

vessel, the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

21.0 Sling Wire Diameters and Master

REV.1.0

links

The minimum wire rope diameter for the construction of wire rope slings attached to loads, w hi ch w i l l be l i f t e d of f s ho r e, i s 1 3m m ( 1 / 2 ” ) A ny w i r e r o pe o f a s m a l l e r di a m et e r i s v e r y susceptible to impact damage and must not be used. The maximum number of lifting legs allowed on a single master link is two have a third leg on a master link but only if leg sling sets must be fitt

this is to avoid out-of-plane forces. It is permissible to it is to be used as a

top lifting leg. Three and four

ed with quadruple assemblies i.e. a master link with two intermediate

links.

21.1

Multi-leg

Slings

W he n l i f t i ng w i t h m ul t i - l e g s l i ng s , t he y a r e r a t e d a t a c e r t a i n ca pa ci t y f r o m 0 º - 4 5 º t o t he v e r t i c al a nd t hi s W L L s ha l l no t be e x ce e de d e v e n i f t he a ng l e i s l e s s t ha n 4 5 º . Whe n us i ng slings in pairs however, you must be aware of the increased loadings in the at an angle.

Page 105 of 247

slings when lifting

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

22.0 Pallets Only purpose built pallets in good condition, without broken boards and blocks shall be used for transporting of loads. Under no circumstances shall any type of pallet be used as putting slings through wooden pallets to lift likely to crush the pallet leaving the contents

a lifting device. For example,

them and their contents is prohibited. Slings are on top unsecured. Pallets shall be lifted by

a

forklift or other certified pallet-lifting accessory. W he n u s i ng p al l e t l i f t e r s ( se e f i g 3 ) i t m us t be e ns ur ed t ha t t he f o r k s o f t he pa l l e t l i f t e r ar e of adequate length for the load to be lift

ed. When a load is lifted using a manually operated or semi-automatic pallet hook, the load must always be in a horizontal position or w ith a slight backward angle.

FIG 3

Pallets that require to be lifted from vessels off

shore are required to be loaded into a container

to facilitate the pre-slinging requirements.

Page 106 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

23.0

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Pre & Post-Use Checks and Safe Use of Lifting Appliances and Lifting Tackle

23.1

Introduction

This Section gives the pre and post checks and brief descriptions of

the more frequently used

types of lifting equipment used on SMEP offshore platforms and onshore.

23.2

Lifting Appliances

and Lifting Tackle

The terms ‘lifting appliances’ and ‘lifting tackle’

will be encountered in this Section and

throughout this section. Refer to the Glossary of T

erms in

23.3

Identification

A ppe ndi x 1 1 for further information

and Certification

Every item of lifting appliances, portable or fixed (used onshore or on

an offshore platform)

must have as a minimum the following legible markings: 1.

Unique Identification

2.

Working Load Limit (WLL) or Safe Working Load (SWL).

3.

The date of inspection

WARNING:

number.

and next due date.

IF AN ITEM OF LIFTING EQUIPMENT HAS NO UNIQUE IDENTIFICATION MARKING, NO WLL MARKING, DATE OF INSPECTION OR IF EITHER THE UNIQUE IDENTIFICATION MARKING, WLL MARKING OR DATE OF INSPECTION CANNOT BE READ WITH CERTAINTY. IT MUST NOT BE USED.

Page 107 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

24.0 Control Of Portable Li Tackle

SMEP.EP200802258279

MANUAL

REV.1.0

fting Appliances and Lifting

A l l por t abl e l i f t i ng a ppl i a nce s and l i f t i ng t a ck l e s ha l l be s t o r e d and co nt r o l l e d i n a l i f t i ng equipment store. This also applies to portable lift

ing appliances and lifting tackle owned by

contractors and sub-contactors using their lifting equipment on Shell Malaysia Exploration and Production offshore or onshore facilitates. A t t e nt i o n i s dr a w n t o She l l ’ s g l o ba l s t a nda r d o n l i f t i ng and ho i s t i ng EP2005-0264-ST

(section

4.11 page 8)

24.1

Equipment

Standards

A l l por t abl e l i f t i ng a ppl i a nce s s uppl i e d m u s t c o m pl y w i t h s t a nda r ds l i s t e d i n a ppendi x 2 o f SMEP Lifti ng an d Hoi sting Syste m, EP 200803208668, Bri tish Standa rds, Interna tional Standard s, or an American Federal Specification. On no account must prototype lifting equipment be supplied without the express, written approval of SMEP's Lifting Technical Authority. If the need arises, SMEP shall, restrict or forbid the

24.2

use of equipment where problems develop/incidents

on occasion, occur.

Storage

Portable lifting appliances and lifting tackle must be housed in rigging stores (or s storage areas) that are fitted with storage facilities

imilar

e.g. racks, bins etc. The store shall be a

purpose designated storage facility where the lifting equipment can be kept secure from unauthorised use. It may be either a transportable containerised rigging store or a controlled permanent store. The store shall include a secure quarantine area for storing equipment no longer fit for service. The stores must have a l platform/worksite’s power supply.

ighting system compatible with the

A ny el e ct r i ca l w i r i ng s y s t e m s i n t he r i ggi ng s t o r e m u s t co m pl y w i t h c ur r e nt s a f e t y r e g ul at i o ns and meet SMEP electrical specifications.

24.3

Certification/Change

out

The portable lifting appliances and lifting tackle must be f for 6 months service offshore, or at the worksite, in

ully inspected, certified and suitable accordance with the latest revision of

SMEP.EP72.ST.0032. The lifting appliances and lifting tackle will

however be changed out prior to the 6 monthly

inspection expiry date. When appliances/tackle cannot be changed-out they must be examined on site by the third party surveyor and the new colour code applied.

24.4

Equipment

Marking and Tracking

Each and every item of lifting equipment (including tackle) must be permanently marked, in accordance with section 5, to facilitate traceability and allow for tracking during its service on the platform or at the worksite.

Page 108 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

Marking shall be by positively attaching a metal t a metal tag is not possible

SMEP.EP200802258279

REV.1.0

ag to the equipment. Where the attachment of

or practical, marking may be done directly on to the equipment but

must not affect the integrity of the equipment. Method of marking lifting tackle and lifting appliances is given i

24.5

n

section 5

.

Contents Register and Other Documentation

Documentation that must be available within a rigging store is liste 1.

A register

of the rigging store's

2.

Current certificate

3.

An issuing

d below:

contents.

for each item of equipment

and returns register,

in the store.

a "T" card, or similar

system to facilitate

the tracking

of rigging store equipment. 4.

Manufacturer’s

operating

and maintenance

instructions

(or copies) as supplied

with

new equipment.

24.6

Rigging Store Control

Lifting appliances and tackle used by SMEP personnel and its contractors’ will, when not be stored in

an on-site

‘Rigging Store’.

Whenever an

item of lifting

in use

equipment is r

emoved

from the rigging store it must be ‘booked out’ in accordance with the booking `system Tee card, or other system).

Similarly it must be ‘booked in’ upon retur

The rigging store shall be controlled by a person who

(register, n to the rigging store.

has the necessary competence to inspect

the lifting equipment before issuing and on its return to check whether it

remains fit for service.

Have a comprehensive knowledge of SMEP.EP72.ST.0032, and is approved by SMEP’s Lifting Technical Authority. The requirements for the Lifting Equipment Focal Point are detailed in A ppe ndi x 1 , C o m pe t e nc y R e qu i r e m e nt s , o f t he L i f t i ng E qui pm e nt M ana g e m e nt Sy s t e m , EP200803208668.

24.7

Colour Coding

Each and every item of lifting tackle in the rigging store s w i t h Section 6

24.8

hall be colour coded in accordance

.

Cleaning of Equipment

Portable lifting appliances and lifting tackle returned to the store shall

be checked for

contaminants and cleaned if necessary prior to inspection and storage. Equipment that has been exposed to seawater splash/spray shall be washed with fresh water, without water pressure. Pressure jets must not be used as they can remove essential l

ubricants, or in the case

of chain blocks may cause the lubricants to migrate to brake components, which requires to be free of lubricant. After washing, the lifting tackle or appliances shall

be dried without the

application of direct heat. Portable lifting appliances and lifting tackle shall not be immersed in lubricant, diesel etc. in an attempt to displace water, in the case of appliances it will penetrate into the brake components. The load chain and components that are clearly visible without dismantling of i.e. pawl pivot spring etc may be lightly lubricated. Care must be taken to avoid lubricant

Page 109 of 247

the appliance

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

entering the brake components and as precaution, before applying the lubricant the brake shall be closed by operating the appliance in the hoisting

24.9

Maintenance

direction.

and Inspection

The supply contractor is responsible for the maintenance, inspection, and where necessary overhaul, and re-certification of the lifting equipment in accordance with the latest revision of SMEP.EP72.0032 . It is SMEP's requirement that all items of li

fting equipment shall be certified at the frequencies

stated in SMEP.EP72.ST.0032. A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-ST

(section

4.7 page 6)

24.10

Damaged Lifting Equipment

W he n a n i t e m o f l i f t i ng e qui pm e nt i s f o und t o be de f e ct i v e , i t s hal l be pl a ce d i n a cl e a r l y marked quarantine area and a third party lifting tackle inspector or surveyor shall be called to decide on one of the following courses of action t o be carried out: Equipment, which cannot be repaired, will be colour coded RED and labelled “DO NOT USE” and be disposed off at the earliest

opportunity.

Equipment, which can be repaired, shall be colour coded RED, and clearly labelled as unfit for continued use. A report, which will include a brief description of the repairs, required, must be attached to the item. A copy of the

report for equipment, that cannot be safely used until

repaired, must be submitted to the platform or worksite Lifting Equipment Focal Point (LEFP).

24.11

Retirement

of Lifting Equipment

Lifting equipment shall be retired (scrapped) when it has reached the end o damaged beyond economic repair/re-certification. SAP shall be updated accordingly.

f its useful life or is

A l l l i f t i ng e qui pm e nt t o be s cr appe d s ha l l be di s po s e d o f f i n s u ch a w ay t ha t t he equi pm e nt cannot be re-used.

24.12

Contractors Using Their Own Lifting Equipment Platforms/Worksites

Contractors equipment shall be as per 14.4.6 and in addition must comply with the

24.12.1

Equipment

On SMEP following:

Marking/Tracking

To distinguish contractor’s equipment from site/platform rigging s

tore equipment, contractor’s

equipment will require some additional (readily identifiable) identification.

24.12.2

Equipment

Register and Other Documentation

W he r e a r i g gi ng s t o r e , o r s m a l l e r qu ant i t i e s o f l i f t i ng e qui pm e nt / ta ck l e a r e us e d on She l l Malaysia Exploration and Production platforms, the following is required: 1.

A register

2.

Current certificate

of the rigging store's

content

for each item of equipment.

Page 110 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

An issuing

AND HOISTING

and returns register

SMEP.EP200802258279

MANUAL

or similar

REV.1.0

system to facilitate

tracking

of the

equipment. 4.

Manufacturer’s

operating

and maintenance

instructions

(or copies) as supplied

with

new equipment.

24.13

Pre-Use Inspection

- Basic Requirements

W he ne v e r l i f t i ng e qui pm e nt i s i ns pe c t e d pr i o r t o u s e t he f i r s t i t e m s t hat m us t be che ck e d ar e : 1.

Item identity

2.

SWL or WLL

number

3.

Date of Inspection

4.

Examination

colour code (if applicable)

A t t e nt i o n i s dr a w n t o She l l ’ s g l o ba l s t a nda r d o n l i f t i ng and ho i s t i ng EP2005-0264-ST 4.9.2 page 7)

Page 111 of 247

(section

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

25.0 Pre-use checks for lifting extended period of time

REV.1.0

appliances not in use

In cases where lifting appliances are not used for an

for an

extended period of time the user shall

ensure that the competent person specifies a special programme of pre-use checks and inservice inspections and thorough examination before it is used. The extent and thoroughness of this programme depends not only on the length of the period that the lifting appliance was out of use but also on the l

ocation of the lifting appliance during this period. Lifting appliances

standing under cover or inside a workshop might require very little extra inspection. Lifting appliances that have been out of use in the

open and therefore exposed to the weather and

atmospheric pollution, etc. might require an extensive appraisal to ensure fitness for work. The programme of pre-use checks and in-service inspections must

contain, as a minimum, the

following checks: 1.

Any checks that are recommended

in the manufacturers

instructions

for the lifting

appliance. 2.

3.

Checking

all hoist chains/ropes

for signs of corrosion/degradation

ensuring that there is

thorough lubrication.

Checking

for evidence

all linkages

of seizure

or partial

seizure

and damage and

and ensuring

that there

is correct lubrication. 4.

Checking

for correct functioning

of all the safety devices.

5.

Checking

seals or other components

6.

Checking

for corrosion

on the structure,

7.

Checking

for structural

integrity,

8.

Testing

for evidence

for example

of every motion for several

of deterioration.

components,

linkages

etc.

cracks, dents, missing

components.

minutes without load and then repeating

the test

w i t h a l o a d.

25.1

Equipment

25.2

Identification

Identification

Markings

Number/Mark

A l l i t e m s o f l i f t i ng e qu i pm ent m u s t ha v e a pe r m ane nt , uni qu e m e ans o f po s i t i v e i de nt i f i ca t i o n relating to ownership, e.g. of lifting equipment can

stamped number, attac not be found it mu

hed plate or label.

st not be used.

If the identity of an item

For positive identification pur

poses

the equipment identification number must be used on all certification and records relevant to that item of lifting equipment. (

25.3

Refer to Section 5

)

Colour Coding System

SMEP require that all lifting equipment owned by them, or used on their worksites or SMEP has the prevailing influence, be thoroughly examined at fixed intervals. (

where Refer 6.3.1

)

A co l o ur co de s y s t e m i s us e d by S M EP t o i ndi ca t e t o t he e nd us e r t ha t i t e m o f l i f t i ng t a ck l e ha s undergone a 6 monthly examination. The colour (code) is changed at ‘set’

Page 112 of 247

6-monthly intervals

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

and lifting tackle shall only be used if

SMEP.EP200802258279

MANUAL

REV.1.0

they are displaying the current colour code. The colour

code for the next 6-month period will always follows the ( Refer section 6

sequence,

Green, Blue and Yellow.

)

25.4

Documentation

Accompanying

Lifting Equipment

The following documentation shall accompany an item of lifting equipment and must be available to the end user if/when required. 1.

Certificate

2.

Certificate

of Conformity of test and examination

3.

Operating

and Maintenance

(if applicable).

Instructions.

Page 113 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

26.0 Wire Rope and Wire CAUTION:

26.1

SMEP.EP200802258279

MANUAL

REV.1.0

Rope Slings

ALWAYS WEAR LEATHER GLOVES WHEN HANDLING ANY FORM OF WIRE ROPE.

Wire Rope

W i r e r ope i s m a nuf a ct u r e d f r o m i ndi v i dua l s t e el bar s t ha t a r e ' dr aw n' t o s i z e t hr oug h a s e r i e s of dies, reducing the diameter of the bar each time until a wire

of the desired diameter is

obtained. Individual wires are then formed and wound into strands. The strands are then w o und t o g e t he r a r o u nd a ce nt r al co r e t o f o r m t he r o pe ( s e e F i g 1 ) . T he co r e o f t he r o pe ca n be of fibre or an additional steel strand. The number of wires in a strand and the number of strands 'construction' of the rope.

in a rope are known as the

There are a variety of arrang

ements in wire rope construction;

designs are produced to give special characteristics such as flexibility, rotation resistant, crush resistant, etc.

CORE: FIBRECORE = FC INDEPENDENT WIRE ROPE CORE = IWRC

CORE WIRE ROPE WIRE

STRAND

CENTRE WIRE Fig 1 Wire

26.2

Rope Terminology

Types of Lay

A w i r e r o pe co m e s i n a v e r i t y o f l ay s , ho w e v e r t he m o s t co m m o n a r e O r di na r y l a y and L a ng' s lay. ‘Ordinary lay’ is the term used to describe a wire rope in which the laid one way and the strands in the

wires in the strands are

rope laid in the opposite direction.

Ordinary lay rope is completely stable, to the extent that come out of a 6 stranded rope when a load is

a slight amount of ‘turn’ will always applied. However, it normally returns to its

former position when the load is released. ‘Lang's lay’ is the name applied strands in the rope are laid in the s

to the type of rope in which the w

ires in the strands and

ame direction.

The two lays can be readily distinguished: with Ordinary lay the i along the rope, while in Langs lay t hey run diagonally across it.

Page 114 of 247

ndividual wires appear to run

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

26.3

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Wire Rope Slings

W i r e r ope s l i ng s a r e m a nuf a ct ur e d i n a cc o r da nce w i t h B S E N 1 3 4 1 4 - 1, f r o m w i r e r o pe , w hi ch meets the requirements of BS EN 12385-4, or an equivalent International Standard. Wire rope slings are the most commonly used lifting accessory and require care in handling and attention in use. They must be protected from severe wear, abrasion, impact loading, crushing and kinking or similar abuse. Wire

rope slings must be

adequately protected from crushing and

chafing damage by the use of adequate packing. The more common types of wire rope sling are shown on Fig 2.

Fig 2 Single Leg and Endless Slings

26.4

Sling Identification

A l l s i ng l e a nd m u l t i -l e g w i r e r o pe s l i ng s m us t ha v e s t a m pe d o n a pe r m a ne nt l y at t a che d m e t a l tag or on the ferrule (see Fig 3). 1.

Identity

2.

SWL.

number.

3.

A sling must also carry the correct colour code.

IMPORTANT: THE CAPACITY OF A MULTI-LEG SLING IS STATED AS A SINGLE SWL, FOR ANY ANGLE BETWEEN 0 AND 45 TO THE VERTICAL, AT THE MASTER LINK.

Page 115 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Wo r k i ng Load Limit

ID No. & WLL Tag

Fig 3 Sling Identity

A s w e l l a s s i ng l e l e g s l i ng opt i o ns , t he y ca n be s u ppl i e d a s do ubl e l e g s l i ngs f i t t e d t o a s i ngl e link (known as a master link) or as multi-leg slings (

3 or 4 legs) fitted to

assembly Fig 4 shows typical arrangements.

L W E

Fig 4 Multiple Leg Slings

Page 116 of 247

g in k r o W e v ti h t c g e ff n e E L

a master link

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

26.5

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Pre-use

The following covers wire rope and wire rope slings. 1.

Check sling unique identification code is present.

and WLL are present

and readable

and current colour

NOTE:

DESTROY (OXY-CUT) SLINGS THAT ARE FOUND TO BE UNFIT FOR USE, SO THAT THEY CANNOT BE ACCIDENTALLY RE-USED.

2.

Check for broken, damaged or kinked wires, which may have been caused by previous incorrect slinging of the load.

3.

Check for signs of abrasion

and similar

damage resulting

from chafing action against

the load or ground/deck. 4.

Check the rope for corrosion,

crushed areas, high stranding,

underlying,

bird caging,

kinks, bulges in the rope, core protrusion, gaps or excessive clearance between strands. 5.

There must be no evidence

of heat burn, or pitting,

(possibly

from welding

equipment)

or similar such discolouration to the sling wires. 6.

Inspect end terminations

7.

Check sling /rope for broken wires.

for damage, deterioration

8.

Ensure that sling thimbles

and security

are secure in the sling eyes.

It is permissible

to display a small amount of movement; the amount shall

for a thimble

not be such that the thimble

may become dislodged. 9.

Check all attached

NOTE:

IF IN DOUBT DO NOT USE AND SEEK ADVICE FROM THE PIC OR WORKSITE SUPERVISOR.

26.6

fittings,

i.e. hooks, rings, links, etc.

Safe Use

1.

When using slings observe

2.

Protect

the following:

them from wear, abrasion,

impact loading,

crushing

and kinking

or similar

abuse. 3.

Always use a sling with a greater

WLL than the anticipated

a.

The exact load weight is unknown.

b.

There is a possibility

c.

There will be an increase

d.

When the load has to be lifted over vulnerable

weight of the load if:

of shock or dynamic loading. in load, through wind effect. plant (because

there is no

alternative route). 4.

Do not assess the required WLL of a multi-leg sling by dividing the load weight by the number of sling legs. There is no way of knowing that all sling legs will carry equal amounts of the load. carrying the ma

With multi-leg slings, it is

jority of the load whilst

possible that two legs could

the other sling legs just ba

is obvious that the load is unbalanced, the leg t

Page 117 of 247

be

lance the load.

ension (not the weight of the

load) in

If it

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

the sling legs carrying the majority of the load must be as sling WLL required.

sessed when determining the

If in doubt do not sling the load but seek advice from the PI

C.

NOTE:

FOR MULTI-LEG SLINGS THE WLL IS QUOTED FOR AN ANGLE OF THE LEG TO THE VERTICAL, AT THE MASTER LINK, OF 0TO 45 .

5.

Be aware that tension

in sling legs varies with the angle of the leg to the vertical

hook. A 'sling angle' is usually denoted

by the angle of the leg to

at the

the vertical at the

lifting point, which is: a.

With two- leg slings,

b.

With three-legged

the angle of the leg to the vertical

slings,

the angle between

(0

°

to 45

°

one leg and the vertical

). (0

°

to

45°). c.

With four-legged

slings,

the angle between one leg and the vertical

(0

°

to

45°). 6.

Never use a sling that is knotted or kinked.

7.

Prepare the load landing

area. Most loads can be lowered on to timber battens

allowing the slings to be withdrawn. Never land a load on 8.

Keep slings away from welding

9.

A multi-leg

to the load slings

or cutting operations.

sling must not be used if, when fitted to the load, the angle from the

v e r t i ca l a t t he m a s t e r l i nk i s g r e a t e r t ha n 4 5 ° ; sling with longer legs must be 10.

Take care not to 'kink' wire rope or a sling.

selected.

A kink in a sling or rope will distort

the

sling/rope, severely affecting its strength (WLL) causing it to be removed from service and destroyed.

Kinks are usually formed

a.

Bad slinging practices, too small a diameter.

b.

By pulling on a loop accidentally

in one of two way

e.g. tensioning

instead of 'untwisted', a kink will

a sling over an acute angle, or round

formed in a sling.

If the sling is pulled

quickly form in the sling (see Fig 5).

Fig 5 How a Kink is Pulled int

11.

s:

Do not wrap a wire rope around a hook (see Fig 6).

Page 118 of 247

o a Wire Rope

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 6 Never Wrap a Wire Rope Round a Hook

12.

Always avoid bending

a sling around small diameters.

The minimum radius around

whi c h a s l i ng s ha l l be be nt i s 6 t i m e s t he di a m e t e r o f t he r o pe . 13.

Do not join two slings together

by, 'threading

the eye' (see F ig 7). If two slings a re to

be joined together, they must be joined with a

shackle of at least the same WLL

as the

slings to be joined.

Fig 7 Joining Slings

14.

Never shorten a sling by tying a knot in it. A knot will cause severe kinking sling when the load is lifted, an

of the

immediate reduction in the WLL of the sling, and

result

in the sling being removed from service and destroyed. 15.

Semi-permanent

terminations

of wire ropes are frequently

made using wire rope clips.

These provide a quick and easy way to terminate wire ropes and when properly applied including the insertion of a thimble in t

he eye of the sling, and the application

of sufficient torque to the securing nuts, provide up to 80% of srcinal rope. Wire rope slings that are made using this method shall not

the strength of the be used for

lifting. U-Bolt rope grips must not be used. The only acceptable rope grip is the double-saddled type (fist grip) Refer to

A pp e ndi x 8 for installation instructions

Page 119 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Figure 8 Application of Rope

16.

When using a sling in a choke-hitch

Grip's

mode, do not force the eye of the sling into closer

contact with the load. This dangerous malpractice and is often called "battening down".

The choke-hitch mu

st be allowed to form

its own 'natural angle’, whic

h will be

about 120 ° (see Fig 9). If forced down, the angle between the sling 'legs' will probably increase beyond 120 ° and become dangerous. 17.

The slinging

of pipes and tubulars

is a very common lifting

operation.

A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-G01

(section

2.1 page 13)

Fig 9 Do Not Batten Down Slings

The slings must be double wrapped with a choke hitch taking care not t on the underside of the pipe or tube bundle (Fig 9).

o cross over the wires

The choke hitch requires to be pulled tight

to contain the bundle and secured using an wire clamp (i.e. Asbro clamp) or a fist grip, If using a fist grip, a tie wrap must then be fi

tted to prevent the reeved eye slipping over the

grip, in case the bundle loosens in transit.

Page 120 of 247

fist

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

a.

The sling positioning

AND HOISTING

SMEP.EP200802258279

MANUAL

must be approximately

REV.1.0

25% (of the total length)

in from either

end of the tubular (Fig 9). b.

Each sling shall have a WLL at least equal to the gross weight of the load.

c.

Ensure that the correct length of slings are used. The recommended the sling leg is 30 degrees from the

safe lifting

angle of

vertical; the maximum lifting angle must never

exceed 45 degrees from the vertical

Do not bend a sling round sharp corners of a load. Use

wooden packing to protect the sling

from sharp edges and to generally increase the radius around which the sling must bend. The w r appi ng o f a f i r e bl a nk e t , o r s i m i l a r , a r o und a be a m i s co s m e t i c a nd u na cc e pt a bl e .

Fig 10 Packing Out a

Load to Prevent Damage to Load and

18.

Multi-leg slings must not be used if there is a possibility equipment to be lifted. Alternative lifting arrangements mu

19.

When lifting a

load, if there is the slightest dou

be slowly lifted clear of the ground, if the

that they will damage the st be made.

bt as to the stability

load then tilts, it must

Tag lines must be attached

to the load and not to the lifting

Page 121 of 247

of the load, be lowered

immediately and re-slung in a more stable position. 20.

Slings

gear.

it must

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

27.0 Wire Clamp (ASBRO)

SMEP.EP200802258279

MANUAL

REV.1.0

Pre-Use Inspection

W i r e cl a m ps m u s t be v i s ua l l y i ns pe ct e d be f o r e t hey a r e us e d a s f o l l o w s : 1.

Check the clamp is of the correct size for the wire rope.

2.

Inspect the saddle for excessive

3.

Inspect the claw for excessive

4.

Inspect

wear, cracks, deformity wear, cracks, deformity

the wedge for excessive

wear, cracks, deformity

and impact damage. and impact damage. and impact damage and check

that the wedge lock is free to move

27.1

Rejection

The clamp needs to be rejected when there is

any obvious excessive wear, cracks, deformity or

impact damage or if the clamp allows the rope to slip

through when landing the bundle thus

allowing the bundle to become slack.

27.2

Care and maintenance

The clamps must be inspected for damage after removing from sling. The Wedgelock shall be greased, if required, and the clamp reassembled and stored in a box marked with the correct size/diameter for future use. The wire clamp must be stored in a dry atmosphere. CAUTION: AFTER LANDING LOAD ON THE TRUCK OR VESSEL, CHECK THAT THE BUNDLE REMAINS SECURE AND THERE IS NO BACK SLIPPAGE OF THE ROPE THROUGH THE CLAMP. BEWARE OF TUBULARS ROLLING OUT TO A FLAT POSITION. THERE MAY BE A DANGER OF LIMBS BEING TRAPPED, IF ANY BACK SLIPPAGE BECOMES APPARENT AND/OR THE BUNDLE BECOMES SLACK, THE CLAMPS MUST BE REPL ACED.

It is a requirement that individual tubulars are double wrapped. If lifted and laid down more than once, it may also

the tubular or load is being

be advisable to lock the choke with a wire

clamp or fist grip.

27.3

After Use

Proceed as follows: 1.

After use and before storing,

check slings for damage and deterioration

in the same

manner as for pre-use inspection. 2.

Never leave slings laying on the ground/deck

where they will be exposed

environmental hazards such as chemical spillage, mechanical from water accumulation. 3.

Return slings to the rigging store and complete

Page 122 of 247

‘returns’

to

damage and soaking

procedure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

28.0 Chain Slings

SMEP.EP200802258279

MANUAL

REV.1.0

and Fittings

It is SMEP policy not to use chain slings for general lifting opera are used for lifting skips and lifting barrels / steel drums, o chain sling configurations

are shown on Fig

tions.

However, chain slings

r similar, from containers.

11. Some chains are

Various

shown with chain ‘shortening

clutches’.

Fig 11 Chain

The rating of chain slings is based

Sling Configurations

on the uniform load method, which give the following

results: Single leg sling

=

1.0

x

SWL of a single leg

Double leg sling

=

1.4

x

SWL of a single leg from 0

Three and Four leg sling

=

2.1

x

SWL of a single leg from 0

Double leg sling

=

1.0

x

SWL of a single leg from 45

°

to 60

°

Four leg sling

=

1.5

x

SWL of a single leg from 45

°

to 60

°

28.1

°

to 45

°

°

to 45

°

Barrel Slings

Barrel slings as shown in Fig 12 must be used for lifting a single barr more than one barrel is to be lifted in

one lift, a drum cage must be used.

Page 123 of 247

el/drum only.

When

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 12 Barrel Sling

28.2

Pre-use

Chain and barrel sling must be visually inspected before they are used as foll 1.

Check sling unique identification

and WLL are present

ows: and readable

and current colour

code is present. 2.

Ensure the grade of the chain sling is suitable

3.

Check for stretch in the individual

4.

Check each leg for distortion

for lifting

duties i.e. grade 8, 10 etc.

legs.

of links e.g. bends, twists,

corrosion,

elongation

and

nicks. 5.

Check for wear between

6.

Check end fittings

chain links and load pins.

e.g. hooks, connectors

etc in accordance

with the appropriate

sections of this standard. 7.

Check all coupling

components

are free from distortion;

cracks and the securing/

load

pins are secured. 8.

Inspect end terminations

9.

Check all attached

NOTE:

DESTROY (OXY-CUT) SLINGS THAT ARE FOUND TO BE UNFIT FOR USE, SO THAT THEY CANNOT BE ACCIDENTALLY RE-USED.

28.3

for damage, deterioration

fittings,

and security.

i.e. hooks, rings, links, etc.

Safe Use

W he n us i ng c hai n s l i ng s o bs e r v e t he f o l l ow i ng : 1.

Protect them from wear, abrasion,

2.

Always use a sling with a greater WLL than the anticipated a. The exact load weight is unknown. b.

There is a possibility

c.

There will be an increase

impact loading,

crushing,

or similar

weight of the load if:

of shock or dynamic loading. in load, through wind effect.

Page 124 of 247

abuse.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

d.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

When the load has to be lifted over vulnerable

plant (because

there is no

alternative route). 3.

Do not assess the required

WLL of a multi-leg

sling by dividing

There is no way of knowing that all sling legs will carry equal

amounts of the load.

With multi-leg slings, it is

carrying the ma

jority of the load whilst

possible that two legs could

the other sling legs just ba

is obvious that the load is unbalanced, the leg t

sling WLL required. supervisor. NOTE:

If in doubt do

be

lance the load.

ension (not the weight of the

the sling legs carrying the majority of the load must be as

4.

the load weight by the

number of sling legs.

If it

load) in

sessed when determining the

not sling the load but

seek advice from a

FOR MULTI-LEG SLINGS THE WLL IS QUOTED FOR AN ANGLE OF THE LEG TO THE VERTICAL, AT THE MASTER LINK, OF TO 0 45 .

Be aware that tension

in sling legs varies with the angle of the leg to the vertical

hook. A 'sling angle' is usually denoted

by the angle of the leg to

at the

the vertical at the

lifting point, which is: a.

With two- leg slings,

b.

With three-legged

the angle of the leg to the vertical.

slings,

the angle between

one leg and the vertical

(0

°

to

45°). c.

With four-legged

slings,

the angle between one leg and the vertical

(0

°

to

45°). 5.

Never use a sling that is knotted.

6.

Prepare the load landing

7.

allowing the slings to be withdrawn. Never land a load on Keep slings away from welding or cutting operations.

8.

area. Most loads can be lowered on to timber battens to the load slings

A multi-leg sling must not be used if, when fitted to the load, the angle from the v e r t i ca l a t t he m a s t e r l i nk i s g r e a t e r t ha n 4 5 ° ; sling with longer legs requires to be selected.

28.4

After Use

Proceed as follows: 1.

After use and before storing,

check slings for damage in the same manner as for pre-

use inspection. 2.

Never leave slings laying on the ground/deck

where they will be exposed

to

environmental hazards such as chemical spillage, mechanical damage. 3.

Return slings to the rigging store and complete

28.5

procedure.

Barrel Lifters

Barrel lifters are u lifter is only used to lift container.

‘returns’

sed to lift barrels ver

tically from half-height co

ntainers.

This type of barrel

the barrel from a container and place it on the deck beside the

Lift height must be minim

ised and personnel mu

Page 125 of 247

st not be allowed beneath the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

barrel.

Various manufacturer

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

s produce this type of barrel lifter and a typic

al top (vertical)

barrel lifter is shown in Fig 13. Care must be taken when using a ‘barrel lifter’ to ensure that standard size.

Non-standard / mod

lifter. They will not ‘fit’

ified barrels must not b

the barrel to be lifted is of e lifted with this type of ba

rrel

the barrel lifter and may drop when lifted. The vertical barrel lifter

must only be used to lift barrels from containers and place them on

the deck alongside the

container.

Fig 13 Typical (Vertical) Barrel Lift Device CAUTION: DO NOT USE BARREL LIFTERS FOR THE PURPOSE OF TRANSFERING BARRELS AROUND THE PLATFORM/PLANT. THE USE OF THIS TYPE OF LIFTING APPLIANCE IS RESTRICTED TO LIFTING BARRELS FROM A CONTAINER AND PLACING THE BARREL ON THE DECK ALONGSIDE THE CONTAINER. BARREL LIFTERS SHALL NOT BE USED IN CONNECTION WITH LIFTING OPERATIONS USING OFFSHORE CRANES.

Page 126 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

29.0 Man-Made Fibre (Webbing)

REV.1.0

Slings

W e bbi ng s l i ng s , w he r e e v e r po s s i bl e , s hal l no t be us e d f o r ge ne r a l l i f t i ng e i t he r o ns ho r e o r offshore.

Webbing slings of nylon or

by visual inspection only.

other man made

fibres are extremely difficu

lt to examine

Weakening of the main body of the sling or stitching by c

mechanical means can all too easily remain undetected until the sling is

hemical or

loaded. Table 1 shows

the webbing sling material colour code and WLL. Generally man made fibre slings are used for slinging fragile loads or

for suspending loads

w he r e t he equi pm e nt co a t i ng ha s t o be pr o t e ct e d i . e . chr o m e t ubul ar s . Generally, the width of a webbing sling governs the 50mm of width for

Simplex

WLL and approximates to 1 tonne per

(single thickness) slings and 1

tonne WLL per 25mm width

for

Duplex (double thickness) slings. Man-made fibre (webbing) slings are manufactured in various formats e.g. as flat web slings w i t h s of t e y es , ha r d e y e s o r e ndl e s s t o s ui t s pe ci f i c r e qui r e m e nt s . T he y c a n a l s o be s u ppl i e d as “round” slings (see Fig 14). W e bbi ng s l i ngs a r e m a nuf a ct ur e d f r om P o l y e s t er , N y l o n o r P o l y pr o py l e ne . E ac h m a t e r i al ha s particular design properties, each of which shall be considered and may affect a webbing sling selection process.

Page 127 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 14 Webbing Slings

Material

Identification

colour for material

(found on label) Polyamide

Green

(Nylon) Polyester

Blue

Polypropylene

Brown

Table 1 Fibre Sling Colours Do not use a webbing sling as a

29.1

transit sling.

Webbing (Round and Flat) Sling WLL Colour Coding

The colour of the outer canvas cover of a round sling denotes the SLING WLL (TONNE) 1

Table 2

WLL of the sling (Table 2)

COLOUR OF OUTER COVER VIOLET

2

GREEN

3

YELLOW

4

GREY

5

RED

6

BROWN

8 10

BLUE ORANGE

Webbing (Round and

Flat) Sling

Page 128 of 247

WLL Colour

Codes

.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

29.2

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Pre-use

W e bbi ng s l i ng s s ha l l no t be u s e d f o r g ene r a l l i f ts , and m us t be u s e d o nl y u nder s t r i ct co ntr o l w he ne v e r de l i c a t e , f r a g i l e o r s pe c i a l i s t l i f t s a r e r e qui r e d. Fibre slings must be visually inspected before they are used as foll 1.

Check the sling unique identification,

ows:

WLL are present and readable

and correctly

colour coded. 2.

Pay extra attention

to webbing slings when inspecting

for damage, look for:

a.

Chafes to the sling. These must be viewed critically, severe.

destroy

b.

Local abrasions

and the sling must be

will cause a serious loss of strength

sling if chafes are

destroyed. c.

Cuts, particularly

at the edge stitching,

will result in a serious loss of strength

and the sling must be destroyed. d.

Friction

burns can be recognised

by a hard, smooth,

shiny surface on the web,

w hi ch w i l l be br i t t l e t o t he t o uch, i f f o und, t he s l i ng m u s t be de s t r o y e d. 3.

Check for chemical

attack, which can be recognised

by weakening

or softening

of the

material such that surface fibres can be plucked or rubbed off, as a powder in extreme cases.

Destroy sling if

chemical damage

4.

Check webbing seams for deterioration.

5.

Give special

attention

the inner surfaces. 6.

to webbing

is found.

sling eyes.

If there is evidence of

Check for damaged stitching

damage at the sling eye

If mildew is found, wash off with fresh water do not use detergents. affect the strength of the webbing and may be removed by washing in

29.3

and cuts to

destroy the sling. Mildew does not water only.

Safe Use

Man –made fibre slings may only be used: 1.

Where there is no practical

2.

Where wire rope could cause crushing

alternative. or surface

damage to unprotected

piping with specialised coatings, rotating components

loads (e.g.

from machinery, fragile

equipment etc). 3.

For awkward lifting,

4.

For applications

where risk would be reduced

where the design specifies

man-made

Observe the WLL mode factor for webbing slings as shown

29.4

Prohibited

fibre slings.

on Fig 15.

Lifts

1.

Man-made

2.

Where sharp edges, rough or abrasive

fibre slings are prohibited

3.

Where exposed temperatures

in the following surfaces

situations:

could cut or tear the sling (e.g. I

beams, etc.) in excess of 80 degrees

Page 129 of 247

Celsius may occur.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

4.

Where exposure

to chemicals

5.

For pre-slinging

loads associated

6.

For any load that may rotate in the sling.

29.5

SMEP.EP200802258279

REV.1.0

is likely (e.g. acids, alkalis, with dynamic factors,

oil, solvents

and paints).

such as vessel operations.

Special Applications

A ny s l i ng u s e d i n s u ppo r t of fa s t r e s cue bo a t s s ha l l be : 1.

Made of continuous

2.

Have extra UV protection

fibre construction

3.

Be replaced

annually

or sooner if required.

There may be the rare occasions where a man-made fibre sling may be exposed to a dynamic lift, shock or snatch conditions i.e. lifting of chrome tubulars offshore. Under such circumstances the lifting operation shall: 1.

Be considered

as a complicated

lifting

operation

and thus be subject

requirements for job planning and operating practice. Refer to 2.

Utilise

slings with a working load rating that is double the actual load being lifted

(e.g. 5 tonne straight lift requires a sling with CAUTION:

1.

to the additional

Section 9.9

a 10 tonne working load rating).

A NYLON (POLYAMIDE) SLING CAN LOSE UP TO 15% OF ITS WLL WHEN WET.

To minimise

loss of strength

when using a webbing sling eye on a hook, the hook bowl

must have a width of more than one-third the inside length of 2.

Protect a webbing sling when passing sling.

3.

Do not permit the eye of a webbing

the webbing sling eye.

it round a surface that may cause damage to the

sling to be opened in excess of 20

°

to avoid

excessive load on the stitching. 4.

Do not cause friction

5.

Do not allow a webbing

heat in a webbing

sling by pulling it round a solid object.

sling to contact hot pipelines

or hot pressure

vessels.

Webbing

slings are adversely affected by heat. 6.

Ensure that a flat webbing sling is loaded evenly across its full width.

7.

Under no circumstances

shall two slings be joined together

two webbing slings have to be joined together they must be 8.

Webbing

slings must not be used as the primary lifting

by 'threading

the eye'. If

joined with a shackle. slings for the transportation

of

goods or cargo to or from a platform, except where noted above.

29.6

After Use

Carry out the following: 1.

Check sling(s)

for damage, deterioration

and contamination

slings and chemically contaminated slings must be destroyed.

Page 130 of 247

before storing.

Damaged

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

2.

AND HOISTING

SMEP.EP200802258279

MANUAL

If a fibre sling is wet it must be thoroughly

REV.1.0

dried before returning

the sling by hanging it in a warm area, not

to rigging

store. Dry

over/on hot pipe work where excessive

heat could damage the sling. 3.

Return sling(s)

CAUTION:

to rigging store and ‘complete

‘returns’

procedure.

FIBRE SLINGS WILL DEGRADE IN ULTRAVIOLET LIGHT AND MUST BE STORED AWAY FROM SUNLIGHT AND OTHER SOURCES OF ULTRAVIOLET LIGHT.

Fig 15 Fibre Sling - Mode Factor

Page 131 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

30.0 Hooks A v ar i e t y o f ho o k de s i gns w i l l be e nc o unt e r e d o n SM E P w o r k s i t e s a nd pl a t f or m s ho w e v er , a l l hooks must be of the ‘safety hook’ that prevents the hook from

type, i.e. a hook that has a mechanical latch arrangement opening until manually

commonly used hook types. A hook that does not

released.

The scissor action self locking type hook shown in Fi as a ‘scissors type’ safety hook.

Fig 16 shows two of

the more

have a safety latch must not be used. g 16, or the BK type are commonly known

The geometry of these

hooks is such that

is passed vertically through the centre line of the hook, t

as long as the load

he applied forces will positively close

the hook. W he n t he ho o k c l o s e s a ca m -l o ck w i l l pr e v e nt t he ho o k f r o m ope ni ng . T o o pe n t he ho o k t he cam-lock requires

manually unlatching.

This design makes the hook

one of the safest types

under normal operational circumstances. However, care must be exercised when of hook to ensure fingers are not pinched in the

using this type

scissor action when used for lifting operations

to and from a moving marine vessel, they must be fit

ted with the additional trigger release

handle. (see fig 16A)

The scissor type hook can however, be unlatched accidentally if the hook is s loading in the opposite direction to which load is Scissor action self locking type hooks fitted to

ubject to shock

normally applied. pennants must be fitted with the additional

trigger release handle Fig 16A.

Fig 16 Hook Types

Page 132 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

Fig 16A Scissor Hook with

30.1

SMEP.EP200802258279

REV.1.0

trigger release handle

Pre-use

Hooks must be visually inspected before they are used as follows: 1.

Check hook WLL is present and readable.

2.

Check that wear on the bearing

surface of the hook is not excessive

no stress/fatigue cracks, or any form of damage (see Figs 17 and 18).

Fig 17 General Hook Inspection

Page 133 of 247

and that there are

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

30.2

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Scissor Hook Inspection

The scissor type self-latching hooks shall be inspected as

follows:

1.

Check generally

2.

Physically

3.

With hook closed attempt to pull hook apart and check gap between hook.

as shown in Fig 17.

close the hook and check that hook closes correctly.

The gap on smaller

hooks (less than 10 tonnes) mu

closing

larger hooks (greater than 10 tonnes) the gap must not exceed 4mm (see 4.

View the hook edgeways

and check for ‘twist’.

must not be used.

5.

Check hook swivel for free rotation,

damage and wear.

6.

Confirm

operate

Fig 18

30.3

Scissors

on

Fig 18).

If either the bottom or the top of the

hook is twisted beyond the centreline the hook

that hook latch mechanisms

faces of

st not exceed 2mm and

freely and has a positive

action.

Type Hook Inspection

Safe Use

Observe the following: 1.

The WLL of a hook applies of the hook. If the hook is

only when the load is correctly

the hook load line, the hook WLL 2.

on the load line

is greatly reduced.

Do not attach more than two sling eyes directly need to be attached to a hook, a suitable shackle the slings’

positioned

eccentrically loaded, or if a load is applied other than on

(see Fig 19).

Page 134 of 247

on a hook. If more than two slings must be used between the hook and

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 19

4.

MANUAL

Do Not Overcrowd

Where the load will have a tendency

SMEP.EP200802258279

REV.1.0

a Hook

to rotate when lifted,

use a swivel hook, or insert

a swivel link between load hook and lifting rope. 5.

Always check to ensure that the hook safety latch, or on scissors

type hooks the latch

release cam has closed correctly before allowing the load to be lifted. 6.

Do not side load, tip load, or back hook (see Fig 20).

Fig 20 Incorrect Hooking Methods

30.4

After Use

1.

Check hook as for pre-use checks.

2.

If applicable,

return hook to rigging

store, and complete

Page 135 of 247

’returns’

procedure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

31.0 Shackles A l l s hac k l e s us e d by S M E P s ha l l pr e f e r a bl y be o f t he al l o y s t e e l v ar i e t y a nd de s i g ne d a nd manufactured in accordance with the US Federal

Specification RR-C-271D grade ‘A’, BS EN

13889 or an equivalent international standard. The use of higher tensile steel tensile steel shackle of si

shackles is to be avoided for reasons of s

afety (e.g. A high

milar size to an Alloy steel shackle is approximately only half

the

strength - confusing the two could lead to inadvertent overload). NOTE:

MILD STEEL SHACKLES SHALL NOT BE USED UNDER ANY CIRCUMSTANCES.

Two basic types of shackle will be encountered on SMEP worksites

and offshore platforms (Fig

21). 1.

'Safety-Anchor'

shackle

with bolt, nut and safety pin, which can have a Bow or Dee

shape body. 2.

'Screw pin' shackle with a pin screwed into one body eye. This type of shackle also have a Bow or a Dee shape body.

can

A B o w s ha ck l e i s g e ne r a l l y u s e d whe r e m o r e t ha n o ne a t t a chm e nt i s t o be m ade t o t he s ha ck l e , i.e. with multi-leg slings.

A Dee shackle is genera

lly used to link two

together and restricted to one attachment only i.e. with single

31.1

items of lifting equipment

sling.

Pre-use Inspection

Shackles must be visually inspected before they are used as follows: 1.

Check shackle

unique identification,

WLL and colour code.

2.

Look for damage to the pin or body threads,

distortion

in any part of the shackle

and

obvious wear on the body or pin of the shackle. Also check for nicks, cuts, cracks or corrosion on any part of the shackle (see Fig 21). 3.

Where a shackle

pin is designed

to accept a locking split pin (safety

pin must be in good condition and of the correct diameter and length see “R” clips cannot be substituted for a split 4.

shackle),

the split A ppe ndi x 9 .

pin and must not be used.

Ensure that the pin and the body are of the same grade material If body and pin do not match the shackle must not

and that they ‘match’.

be used.

W he n a s ha ck l e body i s s u s pe nde d f r o m i t s cr o w n o n a pi e ce o f w i r e a nd t a ppe d w i t h a hammer it shall have a clear 'bell-like ring', if a crack is present the sound.

Page 136 of 247

shackle will have a 'dead'

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Fig 21 Shackle Inspection

31.2

Safe Use

W he n us i ng a s hac k l e , t he fo l l o w i ng s ha l l be o bs e r v e d: 1.

A shackle must be fitted and loaded such that the load line is on the centre line of the shackle and not in such a way that side loads are imposed on the body.

Fig 22 Correct and Incorrect Use of a Shackle with a Hook

Page 137 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

2.

AND HOISTING

To avoid side loads on a shackle

MANUAL

Do not reduce the width between to the inside faces of the

REV.1.0

fit loose spacer/shimming

shackle pin, or fit a shackle with a jaw opening ' 3.

SMEP.EP200802258279

the jaws of a shackle

shackle jaws.

washers at each end of the

gape' that fits the hook. by welding

washers or spacers

Welding heat will seriously wea

ken the

shackle, and invalidate certification. 4.

When a shackle

is used to secure the top block of a set of rope blocks the load on the

shackle (and anchor) is increased by the value of the hoisting e

ffort. Care requires to

be taken to ensure that the structure, attachments and shackle are all of adequate WLL.

Fig 23 Use of Shackle with Sheave Block

5.

Do not use a single rope (sling) The load is unstable and if it s

passed over a shackle

Fig 24 Use of Slings with

6.

screw pin to lift a load (Fig 24).

hifts, the rope could unscrew the shackle pin.

Always place the shackle with the pin uppermost located in the shackle body (Fig 24).

Page 138 of 247

Shackles

in the hook and with the sling eyes

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

31.3

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

After Use

On completion of use: 1.

Thoroughly procedures.

clean the shackle

2.

Coat threads and body of shackle shackle bodies.

3.

and inspect the shackle

with light machine

A shackle must always

Return the shackle(s)

in accordance

oil. Do not separate

be stored as a c

to rigging store and complete

Page 139 of 247

with pre-use

pins and

omplete, certified unit.

‘returns’

procedure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

32.0 Eyebolts Eyebolts are one of the most widely

used items of lifting tackle, however, only collared eyebolts

must be used.

Fig 25 Types of Eyebolt and Eyebolt Terminology

32.1

Eyebolt with Link

This type of eyebolt is preferred for general lift cannot be kept to a single plane. An eye

ing (see Fig 25). It can be used where loading bolt with a link can be loaded in any direction to

full

W L L pr ov i de d t hat t he a ng l e o f t he l o a d t o t he a x i s o f t he s c r e w t hr ea d do e s no t e x ce e d 1 5 ° . For greater angles (up to 45

32.2

°

) the WLL requires to be de-rated by a reduction factor of 0

⋅

65.

Collar Eyebolt

A c o l l a r e ye bo l t ( s e e F i g 2 5 ) m u s t hav e a t hr e a d t ha t i s r un o u t a nd r e ce s s e d unde r t he co l l ar , so that it seats correctly on the load. The WLL of a collar eyebolt is stated for vertical lifts only.

A pair of collar eyebolts can however be u

sling to lift at an angle and 45

°

sed in conjunction with a shackle and two-leg

to the vertical but the WLL must be de-rated. For

collar eyebolts must be de-rated by 50%

Page 140 of 247

angles between 0

°

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

W he r e m o r e t ha n o ne e ye bo l t i s us e d t o l i f t a l o ad, t he e y e bol t s m us t ha v e t he s a m e W L L . I n instances where the eyebolts will not be

equally loaded, it is essential that

adequate capacity. The plane of each eyebolt shall align with t

each eyebolt is of

he point of lift, e.g. the

hook,

w i t h a m a x i m um v ar i a t i o n o f 5 ° either way.

WARNING

DYNAMO EYEBOLTS, COLLAR-LESS EYEBOLTS WITH A SCREWED SHANK, OR THREAD DIAMETER OF LESS THAN 12mm ARE NOT TO BE USED FOR LIFTING.

CAUTION

EYEBOLTS MUST NOT BE USED FOR OFFSHORE LIFTING.

32.3

Pre-use Inspection

Eyebolts must be visually inspected before they are used as follows: 1.

Check eyebolt

unique identification

and WLL, are present and readable,

and colour

coded. 2.

Generally

clean the eyebolt

and inspect

the eyebolt

for bent shank, deformed

eye,

cracks and nicks and in particular for thread damage. If defects are found the eyebolt must be scrapped. 3.

Check that the threaded

hole into which the eyebolt

is to be fitted is clean, its thread is

in good order and there is no build-up of dirt/grease in the bottom of t wi l l pr e v e nt t he e ye bo l t co l l ar f r o m s e a t i ng.

Fig 26 Eyebolt Inspection

Page 141 of 247

he hole that

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

32.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Safe Use

Observe the following: 1.

Check that the eyebolt thread and the hole thread are compatible. mismatched any attempt to force-mate will result in a serious reduction in lifting

2.

Check that the surface

If threads

are

capacity and will render both threads (male and female) unfit for further use. area around the hole (under the eyebolt

collar)

is clean, and

w i l l no t hi nde r t he e y e bol t c o l l a r f r om s e a t i ng al l r ou nd. T he t hr ea de d hol e r e c ei v i ng an eyebolt must have sufficient thread depth to ensure that the before the eyebolt thread reaches the bottom of the 3.

Do not fit a hook directly

on to an eyebolt;

use a shackle

Fig 27 Use of Eyebolt

7.

Do not use

excessive leverage

to tighten an

eyebolt collar will seat threaded hole. (Fig 27).

with Shackle

eyebolt that will not

seat correctly

with

normal leverage (Fig 28). Over-tightening of an eyebolt can cause stretching of the shank under the collar resulting in serious (but hidden) damage, which will cause a reduction in the WLL. Use no greater leverage than a spanner compatible with t eyebolt thread size.

Fig 28 Eyebolt Tightening

Page 142 of 247

he

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

8.

If a single

AND HOISTING

eyebolt is used

MANUAL

for lifting and

or twist, a swivel must be used in the

SMEP.EP200802258279

REV.1.0

there is a

possibility that the

load will revolve

lifting gear to prevent the eyebolt from being

unscrewed. 9.

When using mo

re than one

align with the point of lift

collar eyebolt for

lifting if the plane

of an eyebo lt will not

, a shim may be used under the eyebolt collar. The shim

thickness must not exceed half of one t

hread pitch and the outside diameter of the shim

must be the same diameter as the eyebolt collar diameter (Fig 29).

Fig 29 Eyebolt Alignment

7.

Under no circumstances

must an eyebolt

be over-tightened

in an attempt to achieve

correct alignment. 8.

Eyebolts

used in clearance

holes with back nuts shall have some locking device fitted

to the nut to prevent the nut from unscrewing. The nut shall

be of a grade compatible

wi t h t he e y e bo l t . 9.

Use a tapered washer if an eyebolt

10.

When using eyebolts

is used on a tapered surface (Fig 30).

Fig 30 Fitting Eyebolt to

in conjunction

sling legs possible are used so as t loading

Uneven Surface

with a two-legged o minimize:

a.

Inclined

b.

Angle at the hook from the vertical.

at eyebolts,

and

Page 143 of 247

sling ensure that the longest

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

32.5

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

After Use

On completion of use: 1.

When an eyebolt is removed ensure that the tapped hole is suitably damage and deteriora tion. Check eyebolt for an y damage that may

2.

Lightly

protected against have been

incurred during use. coat with oil to protect machined

surfaces,

i.e. threads and underside

of

eyebolt collar. 3.

32.6

Return eyebolt(s)

to rigging store and complete

‘returns’

procedure.

Swivel Hoist Rings

The swivel hoist ring performs a similar function to a link eyebolt

but with a greater and safer

range of out-of-vertical lift capabilities. The swivel hoist ring will swivel 360º and its lifting bail ring will pivot through 180º angled lifts between 0º and 90º. Hoist rings are ava

unrestricted through

(Fig 31). There is no reduction in SWL for ilable with either UNC or Metric thread

sizes; the coloured washer on the swivel identifies thread type: Red denotes UNC thread. Silver denotes Metric thread. Hoist rings with a UNC securing thread are available in sizes from 800lb to Load Limit (WLL). Metric thread types are available i

30,000lb Working

n sizes from 400kg to 16,900kg WLL.

180 PIVOT

360 ROTATION Fig 31 Hoist Ring

Page 144 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

32.7

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Pre-use

1.

Swivel hoist rings must be visually

2.

Check swivel hoist ring unique identification

inspected

before they are used as follows: and WLL are present

and readable,

and

colour coded. 3.

Inspect for defect to the threads,

4.

Check ring bail for elongation, through 360

32.8

°

corrosion, possible

wear or damage.

wear, freedom of movement

, check pivot moves freely through 180

°

and free rotation

.

Safe Use

Observe the following: 1.

Check the tapped hole for cleanliness

and thread rating

2.

Install and tighten to manufacturer’s flange meets the load surface.

3.

Do not use spacers between

4.

Do not exceed the swivel hoist ring WLL.

5.

When using lifting

recommended

torque.

bushing flange and mounting

Make sure the bushing

surface.

slings of two or more legs, ensure that the forces in the legs are

calculated using the angle from the vertical to the leg

and select the proper size swivel

hoist ring to allow for the angular forces.

NOTE: SLING ANGLES MAY DE-RATE SLING MEMBERS (CHAIN, ROPE, OR WEBBING) BUT WILL NOT DE-RATE SWIVEL HOIST RING CAPACITY.

32.9

After Use

Check as for pre-use, return to

rigging store and complete ‘returns’ procedure.

Page 145 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

33.0 Beam Clamps A be a m cl am p i s a n i t e m of po r t a bl e l i f ti ng e qu i pm e nt , w hi ch i s us e d t o a t t ac h a ho i s t or similar portable lifting equipment to a structural beam capable of sustaining a load. The onshore/offshore industry uses only the type which actually clamp onto and grip the beam by means of a threaded adjusting bar (see Fig 32).

Beam clamps are often used as an anc

hor

point for manually operated hoists. The more common types of beam clamp used in offshore and onshore are shown on F are designed for v

ertical lifts only and mu

st not be subjected to side

loading.

ig 32, they Where some side

loading is expected to occur in a beam clamp lifting operation, a beam clamp specially designed for side loading shall be used (see F ig 33).

Fig 32 Typical Beam Clamps

33.1 1.

Universal

Superclamps

The only clamp that will accept lateral beam is the clamp

shown in Fig 33.

2.

Use as an anchor point for lifting

3.

Loading

and longitudinal

side loading

in line with the

This clamp is suitable for: and pulling

at any angle (to 90 degrees)

without

de-rating,

longitudinally. Low headroom use.

Page 146 of 247

both laterally

and

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 33 Universal Super clamp

33.2

Pre-use Inspection

Check as follows: 1.

Check beam clamp unique identification,

WLL, date of inspection

and next inspection

due date are present and readable. 2.

Ensure that the adjustable

3.

Inspect for damage, distortion

screw rotates freely and deterioration,

if defects are found the beam clamp

must not be used. Report defects and place a notice on the beam clamp must not be used for lifting until defect is 4.

Generally

clean the beam and inspect

defects are found the beam shall not be used,

beam clamp indicating that rectified.

for damage,

defects

and deterioration,

if any

do not attempt to repair the beam.

Report defects to the worksite supervisor.

33.3

Beam Clamp Safe Use

Observe the following: 1.

Do not exceed the WLL of the beam clamp or the WLL of the beam to which the clamp is to be secured.

2.

Ensure that the beam clamp is correctly clamped to the beam and that the centre line of the beam clamp suspension point is in alignment with the centre line of the beam.

3.

Use standard

beam clamps for vertical

lifts only, no side loading

the beam is not permitted.

Page 147 of 247

longitudinally

along

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

is expected,

SMEP.EP200802258279

MANUAL

REV.1.0

4.

Where side loading

5.

If two clamps are to be used on a beam for one lift, a spreader

use the beam clamps shown in Fig 33. bar must be used to

ensure equal and vertical loading.

33.4

After Use

Proceed as follows: 1.

Clean the clamp(s)

2.

Return clamp(s)

and inspect as for pre-use inspection.

to rigging store and carry out ‘returns’

Page 148 of 247

procedure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

34.0 Beam Trolleys A be a m t r ol l ey i s a n i t e m of po r t a bl e l i f t i ng e qu i pm e nt us e d t o at t ac h a ho i s t o r s i m i l ar portable lifting equipment to a structural beam capable of sustaining the load to be also facilitates horizontal movement of the load along t

lifted, it

he beam.

A t r o l l e y w i l l be e i t he r a ' pus h' o r ' g e a r ' t y pe a nd c a n be e i t her pe r m ane nt l y f i t t e d, o r removable (Fig 34).

Fig 34 Typical Beam Trolleys

34.1

Push Type Trolleys

Push type trolleys are generally suited to low suspension levels,

light loads (usually 2 tonne

maximum) and infrequent use.

34.2

Gear Type Trolleys

Gear type trolleys are usually preferred when loads in excess of 2

tonne are handled and/or

accurate positioning of the load is required. They are usually traversed by an endless hand chain and are more suited to high suspension levels and regular use.

34.3

Beam Trolley Installation

A C o m pe t e nt P e r s o n m u s t c a r r y o ut t he i ns t al l a t i o n o f a t r o l l ey t o a be a m . B e a m t r ol l e y s a r e i n the main adjustable to su

it a specific range

of beam flange widths.

Adjustment is achieved by

means of a screwed adjusting bar or by the positioning of spacer washers on bar between the side plates.

the trolley load

W he n s e l e ct i ng a t r o l l e y , t he o pe r at i ng cha i ns ( t r ol l ey a nd ho i s t uni t ) m us t be l o ng e nou g h t o hang approximately half a metre above the operating level of the l

Page 149 of 247

oad.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

WARNING: BEAM TROLLEYS ARE DESIGNED FOR A VERTICAL LOAD HANDLING ONLY AND ARE NOT SUITABLE FOR SIDE LOADING BEAM END STOPS (TO PREVENT THE TROLLEY RUNNING OFF THE BEAM) MUST BE PRESENT ON ANY BEAM WHERE A TROLLEY IS USED. THE PLATFORM STRUCTURE MUST NOT BE USED TO LIMIT TROLLEY TRAVEL. END STOPS MUST CONTACT THE TROLLEY BODY. TO PREVENT THE TROLLEY MOVING UNDER GRAVITY THE BEAM ON WHICH THE TROLLEY IS USED MUST BE HORIZONTALLY LEVEL UNDER ALL LOADING CONDITIONS.

34.4

Anti-tilt

Device

Most trolleys are fitted with an anti-tilt

device that must be adjusted to just clear the underside

of the beam.

34.5

Pre-use Inspection

Check as follows: 1.

Check trolley

unique identification,

WLL, date of inspection

and next inspection

due

date are present and readable. 2.

Check cross bolts, side plates and assemblies

for security

and signs of damage or

deterioration; check for distortion of the side plates and/or load bar. 3.

Check bearing

stubs and bearings

for evidence

of wear. (If contaminants

bearing seals, rapid wear and/or seizure will 4.

Check trolley

generally

penetrate

the

result).

for freedom of operation.

Check rollers for free running

and

for any wear at outside diameters. 5.

Where fitted,

check hand chain and wheel for deformation

the 'split' link, for distortion. Never attempt to straighten may already have been damaged beyond repair and is unfit for use. 6.

Check also for the possibility

of incorrectly

substituted

and chain links, especially a distorted chain link, it

components.

(Someone

may

have tried to make one good trolley from two unserviceable trolleys). 7.

Generally

clean the beam and inspect

for damage,

defects are found the beam shall not be used,

defects

and deterioration,

if any

do not attempt to repair the beam.

Report defects to the worksite supervisor. 8.

Before a trolley

is fitted to a beam, ensure that the track width and shape of trolley

whe e l s / r o l l e r s i s co m pa t i bl e w i t h t he be am . 9.

After fitting

the trolley

to the beam, ensure that trolley

centreline

is aligned

with

centreline of the beam web. 10.

Where applicable,

check that operating

height of hand chain is compatible

with beam

height. 11.

Confirm that 'end stops' are fitted to the beam.

12.

When fitting

the trolley

to the beam adjust the wheels/rollers

so that there is 6 mm

clearance overall (i.e. 3 mm max each side between the roller rim and the outer edge of the beam (Fig 35).

If the trolley cannot be adjusted to give the required clear

it must not be used.

Page 150 of 247

ance

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

13.

Function

AND HOISTING

test the trolley

SMEP.EP200802258279

MANUAL

REV.1.0

without load; run it along the beam.

'sticks', 'slips' or has any form of malfunction. If t

Do not use a trolley

that

he hand chain 'jumps' or does not

operate smoothly it is not correctly locating in the wheel pockets and t

he trolley must

not be used.

Fig 35

CAUTION:

Beam Trolley

Checks

DO NOT OPERATE A TAPPERED SIDE PLATE OR TAPPERED TREAD WHEELED TROLLEY ON A FLAT FLANGE BEAM. DO NOT OPERATE A STRAIGHT SIDE PLATE TROLLEY WITH FLAT TREAD WHEELS ON A TAPPERED FLANGE BEAM

34.6

Safe Use

Observe the following: 1.

Do not use the hand chain for lifting

or slinging

purposes,

or for any form of load

support. 2.

Do not shock load the trolley

3.

Do not allow the hand chain to tangle,

4.

Ensure that the trolley

5.

Keep the trolley

anti-tilt

and associated

equipment.

or to become twisted

device is adjusted

or kinked.

so that it is just clear of the beam.

wheels and the beam free of grease and contaminants

foreign bodies, which may then wedge under the trolley wheels. 6.

Ensure that trolley

7.

Do not operate

a tapered

tread wheels on a flat flange beam.

8.

Do not operate

a straight

tread wheels on a tapered

34.7

is used for vertical

lifts only.

flange beam.

After Use

Proceed as follows: 1.

Clean the trolley

and inspect

2.

Return the trolley

to rigging store and carry out ‘returns’

as pre-use inspection.

Page 151 of 247

procedure.

that may collect

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

35.0 Plate Clamps Plate clamps are available in two basic designs: 1.

Horizontal

Plate Clamps:

These are used in pairs and usually

suspended

sling from a beam. They are intended for lifting and moving metal plate

by a two-leg in the

horizontal position only. 2.

Universal

Plate Clamps:

These clamps are intended

for lifting

and moving metal plate

in the vertical position.

Horizontal

Plate Clamps

Universal

(Vertical)

Plate Clamp

Fig 36 Plate Clamps

Selection of a plate clamp for lifting one plate

at a time will be subject to three

main

considerations: 1.

How the plate is to be transported

2.

The weight of the plates to be handled,

and stacked i.e. horizontally

3.

The thickness of the plate, which will determine appropriate jaw opening.

which will determine

or vertically. the WLL of the clamp(s).

the correct model of clamp with the

It is important to select a clamp with WLL as close to the weight of the plate (never below) as possible. An over-specified c lamp will not be as efficient as one with a WLL just above the w e i g ht t o be l i f t e d. For lifting more than one plate (in the horizontal position only) specially designed clamps known as Sheet Bundle Clamps must be used (Fig 37).

NOTE:

PLATE CLAMPS ARE NOT SUITABLE FOR SUB-SEA WORK.

Page 152 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 37 Example of a Sheet Bundle Clamp

35.1

Pre-use

Check the following: Check plate clamp unique identification, WLL, date of inspection and next

inspection due date

are present and readable.

35.2 1.

Horizontal

Plate Clamps

Check plates (to be lifted)

and clean off mill scale, grease,

paint, or any coating that

could prevent the clamp gripping surfaces from making positive contact with the plate. 2.

Inspect clamp cam segment

for wear or distortion.

Check that the teeth are sharp and

free from dirt. 3.

Inspect clamp body for damage, fractures

4.

Check clamp opening

5.

Check cam segment

6.

Fig 38 shows various acceptable

and closing

or deformation.

operation.

shaft and cotter pin for any wear or damage. horizontal

plate clamp lifting

Page 153 of 247

arrangements.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 38

35.3

Universal

1.

Check as for horizontal

2.

Check operation

SMEP.EP200802258279

MANUAL

Horizontal

(Vertical)

REV.1.0

Plate Clamps

Plate Clamps

clamps above, but see also Fig 39

of locking

assembly.

Operation

must be positive

and not heavy or

rigid. 3.

Check the lifting

eye for wear and/or deformation.

4.

Check operation

of the spring by pressing

on the hoisting

This applies force on the spring. The spring must have no tension.

Page 154 of 247

eye in the closed position. signs of corrosion or loss of

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 39

35.4

SMEP.EP200802258279

MANUAL

Universal

REV.1.0

Plate Clamp

Safe Use of Plate Clamps

Observe the following: 1.

Horizontal

Plate Clamps for carrying

plate horizontally.

a.

Do not attempt to lift more than one plate at a time.

b.

Always use horizontal

c.

When using multiple

plate clamps in pairs pairs of clamps ensure that the load is shared equally

between the clamps. d.

Firmly push the clamp against the plate; if the clamp is fitted with a pretension system no further

operation is required.

tension system ensure that the inner side the plate edge when tightening of the e.

If it does not have

a pre-

of the clamp body is located against clamp occurs.

Ensure equal load on each clamp and that the load is balanced.

The clamps

must remain positioned against the plate throughout the entire lifting operation. If a gap appears between plate and clamp, lower the

plate to a

safe position and investigate cause of clamp movement. f.

When moving plate, take care not to snag or lower the plate onto obstacles

or

structures, which could cause instability and possibly release the load from the clamps. g.

Lower plate onto battens

to enable removal of clamps,

never use the hoist to

remove clamps. 2.

Universal

(Vertical)

clamps for carrying

plate vertically

a.

Clamp plates used to carry plate vertically

are also suitable

b.

turning steel plates. Determine the weight and size of the plate to be lifted.

for lifting

and

This will determine

the

W L L and t y pe o f cl am p t o be us e d. c.

These clamps are used to lift, turn or transfer

Page 155 of 247

only one plate at any one time.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

d.

Vertical

e.

When using more than one clamp ensure clamps are equally

clamps can be used individually,

in pairs, or in multiples.

f.

in the open position

loaded.

onto the plate so that the jaw of the clamp rests

completely on the plate, and then set

the locking assembly to the ‘LOCK’

position. g.

Before lifting,

check the clamp to ensure that it is locked onto the plate.

h.

When using two clamps to lift a plate, a spreader

bar must be used to prevent

overloading the clamp and slippage due to angle increase (see fig 38). Reference shall be made to manufacturers safe working load charts with respect to clamps used at angles, especially when used with

endless chain

slings. i.

When lowering

the load, lower the hoist sufficient

to enable a complete

disengagement of that the plate is adequately supported and cannot sl that the lifting sling is j.

To minimise

ip and

loose enough for the clamp to be removed.

damage of the cam segment

when not in use leave clamp in an

open position. CAUTION UNIVERSAL PLATE CLAMPS CAN LIFT A PLATE FROM HORIZONTAL TO VERTICAL AND VISA-VERSA, BUT MUST NOT BE USED TO TRANSPORT PLATES HORIZONTALLY. DO NOT USE PLATE CLAMPS FOR THE PURPOSE OF TRANSFERING STEEL PLATE AROUND THE PLATFORM/PLANT. THE USE OF THIS TYPE OF LIFTING APPLIANCE IS RESTRICTED TO SITUATIONS WHERE PLATE IS BEING REMOVED FROM A RACKING SYSTEM, OR IS BEING MOVED SHORT DISTANCES WHERE THE PLATE CAN BE RETAINED JUST ABOVE THE DECK/GROUND. PLATE CLAMPS SHALL NOT BE USED IN CONNECTION WITH LIFTING OPERATIONS USING OFFSHORE CRANES.

Page 156 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

36.0 Rigging Screws /

SMEP.EP200802258279

MANUAL

REV.1.0

Turnbuckles

The terms `rigging screw' and `turnbuckle' are often applied to a piece of rigging equipment, w hi ch, t hr o ugh t he u s e o f s cr e w t hr e a ds , pr o v i de s a m e a ns o f l e ng t h a dj us t m e nt or t e ns i o ni ng in a secured rope.

There are differences however, between a rigg

ing screw and a turnbuckle.

A r i gg i ng s cr e w co ns i s t s o f a t ubul a r ( cl o s e d) body s o m e t i m e s r e f e r r e d t o a s a bo x o r bo t t l e w i t h a s cr e w ed f i t t i ng e ach e nd ( s e e F i g 4 0 ) . View Holes

Fig 40 Rigging Screw

A t ur nbu ck l e c o ns i s t s o f t wo r e i ns wi t h a bo s s a t e ac h e nd ( ope n body ) w i t h a s cr e w e d f i t t i ng each end (see Fig 41).

Fig 41

Turnbuckle

In each case, the body is internally threaded, one end end with a left-hand thread. Rotating the body of

with a right hand thread and the other the unit will thus either increases or

decreases the overall length of the screw asse

mbly. The length of the body dictates the amount

of adjustability (more commonly known as `Take-up'). In the interests of safety, open

bodied

screws are preferred. With closed body screws, there is a possibility of `over-opening' and consequent failure due to lack of load bearing thread. When closed rigging screws are used they must be fitted with v

iew holes (refer to fig

40).

When in use, the threads

must not be

screwed beyond these holes to prevent inadvertent over opening. W i t hi n S M E P , t he s e i t e m s a r e cl as s i f i e d as ‘ l i f t i ng e qui pm e nt ’ a nd m u s t ha v e c e r t i f i ca t i o n. However, they shall not be used for lifting purposes. Rigging screws and turnbuckles are normally supplied in a galvanised condition with a variety of end fittings as illustrated in F ig 42. It is recommended that once the ideal length required has been calculated, a s selected which meets this dimension at `Mid-position' to

36.1

crew shall be

allow adjustment in each direction.

Pre-use

Check as follows: 1.

Check rigging

screw/turnbuckle

unique identification,

inspection due date are present and readable

Page 157 of 247

WLL, date of inspection

and next

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

2.

Check for thread damage, stretch

3.

Check for cracks or distortion

to body (Fig 42).

and possibility

4.

Check for cracks or distortion

to both end fittings,

of a bent thread bar.

especially

at the neck of the shank.

Jaw

Hook Note: the hook has reduced capacity

Eye

Fig 42 Turnbuckle Inspection

36.2

Safe Use

Observe the following: 1.

Select the correct type and size for the job. (Thread size determines

SWL). Refer to

Manufacturer’s load charts. 2.

If a turnbuckle

is to be used in an application

where vibration

fittings shall be secured with locking nuts wire to prevent l

is present,

the end

oosening alternatively it may

be secured with locking wire to prevent loosening (Fig 43). 3.

If the rigging screws/turnbuckles present, it shall be specified that they

are to be used in an environment

where vibration

are fitted with locking wire or split pins, lock

nuts can be used but they may slacken.

Page 158 of 247

is

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

FIT LOCKING WIRE AT EACH EN D TO PR EV EN T SC RE W TU RN IN G

Fig 43

4.

If a rigging be required.

5.

Locking

Wire Fitted

screw is used with hook end fittings (Refer to Manuf

Never over tighten

rigging

acturer’s load

charts).

screws/turnbuckles.

Page 159 of 247

to Tu rnbuckle

a reduction

in working load limit will

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

37.0 W edge and Socket W e dg e and s o ck e t a s s e m bl i e s ar e us u al l y e nco unt e r ed a s t e r m i na t i o ns o n cr a ne r u nni ng r ope s . Fig 44a, b and c show the ass

embly arrangement of a typical wedge and socket arrangement.

Fig 44a

Wedge and Socket Arrangement

Fig 44b Terminator wedge and socket arrangement

Page 160 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

W r o ng Rope backwards

AND HOISTING

SMEP.EP200802258279

MANUAL

W r o ng W e dg e B a ck w a r ds

Fig 44c Termination of

REV.1.0

W r o ng Dead end clamped to live end

Correct

the Crosby “Terminator” Wedge and Socket

*Wedge and Socket Tail Length Standard

6 to 8 strand wire rope

Rotation

A m i ni m um o f 6 r o pe di a m e t e r s , but no t l e s s than 152 mm (6")

Resistant

Wire Rope

A m i ni m um of 2 0 r o pe di a m e t e r s , but no t l e s s than 152 mm (6"). Table 1

Rope Size

(10 mm) 3/8”

(13 mm) ½”

(16 mm) 5/8”

(19 mm) ¾”

(22 mm) 7/8”

(25 mm) 1”

(29 mm) 1-1/8”

(32 mm) 1-1/4”

Clip Size

(10 mm) 3/8”

(13 mm) ½”

(16 mm) 5/8”

(19 mm) ¾”

(22 mm) 7/8”

(25 mm) 1”

(29 mm) 1-1/8”

(32 mm) 1-1/4”

*Torque Ft./lbs.

45

65

95

130

225

* The tightening torque values shown are based upon the threads lubrication.

225

225

360

being clean, dry, and free of

Table 2

37.1

Pre-use

Check the following: 1.

Check the wedge and socket unique identification,

WLL and rope size are present and

readable. 2.

Check that the wedge/socket

are the correct size for the rope.

3.

Check the dead end of the rope length (Table 1). Ensure rope grip is secure. A cci de nt al s l ack e ni ng o f t he r o pe gr i p co ul d sl a ck e n t he r o pe and di s l o dge t he w edge , resulting in the wedge dropping out.

4.

Check the rope around the wedge for corrosion

5.

Check for signs of cracking/distortion

and security.

on the socket body.

Page 161 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

37.2 1.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Safe Use If the wedge and socket is to remain in use, periodic

inspection

and renewal

of the

termination must be carried out throughout the life of the rope. a.

After installation, a

good covering

of grease mu st be applied

protection against weather.

Page 162 of 247

at the bend

as

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

38.0 Lifting Nipples and Lif Lifting nipples and lifting caps shall be

38.1

SMEP.EP200802258279

MANUAL

REV.1.0

ting Caps certified and approved for lifting.

Pre-Use

Before use, a check shall always be carried out to: Ensure that the thread section on the pipe undamaged

38.2 1.

and on the lifting nipple or lifting cap are

Safe Use The lifting

nipple or lifting

cap is correctly

installed,

and that the thread dimension

and type are the same. 2.

When moving a load with lifting

nipple or lifting

barred off.

Page 163 of 247

cap, the area below the travel path is

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

39.0 Runway Beams Runway beams are specially fitted beams, or structural beams that have been tested and certified for lifting purposes and the attachment of items of

lifting equipment.

Three basic types of runway beam are found on offshore platforms (Fig 45). 1.

Rolled Steel Joists (RSJs)

2.

"I" or "H" Beams

3.

Universal

Beams

RSJ UNIVERSAL BEAM

I or H

Centre line of suspension point must always align with

centre line of beam/column

Fig 45 Types of Runway Beam

39.1

Beam Identity

Certified runway beams must have: 1.

Unique identification,

SWL, date of inspection

and next inspection

due date are

present and readable Identification marking (Fig 46). 2.

Zebra striping

to indicate

they are runway beams and to improve visibility.

The striping must: a.

Be at an angle 30-60 degrees

b.

Be 40-150 mm wide; and

c.

Consist

of two contrasting

to the horizontal;

colours,

yellow and black.

Black Y el l ow Fig 46 Beam Identity

Page 164 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

39.2

Uncertified

AND HOISTING

MANUAL

used for lifting purposes but is not certified for

lifting, a risk assessment must be carried out and a li The lifting plan together with

equipment etc must be fo

REV.1.0

Lifting Beams

If a section of the platform structure is to be details.

SMEP.EP200802258279

fting plan prepared Refer to section 8 for

a sketch, details of the item

rwarded to the appropriate Asset St

to be lifted and the

lifting

ructural Engineer for approval.

CAUTION UNDER NO CIRCUMSTANCES SHALL PIPEWORK BE USED TO SUPPORT ANY PIECE OF LIFTING EQUIPMENT.

39.3

Pre-use Inspection

Before using a runway beam the following checks must be carried out: 1.

Check beam unique identification,

WLL, date of inspection

and next inspection

due

date are present and readable. 2.

Confirm

that the total load to be suspended

from the beam will not exceed the beam

WLL. 3.

Generally

clean the beam and inspect

for damage,

defects are found the beam shall not be used,

defects

and deterioration,

if any

do not attempt to repair the beam.

Report defects to the PIC and worksite supervisor. 4.

Where a beam is bolted to the supporting

structure

ensure that all bolts/nuts

are

secure and in good condition. 5.

Check, where appropriate,

that end stops are fitted to the beam and are adequate

prevent a travelling lifting device running off the beam. The platform structure must not be used to stop a travelling lifting device fitted

to a beam

.

Fig 47

Runway Beam Inspection

Page 165 of 247

to

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

39.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Safe Use

Observe the following: 1.

No more than one item of lifting the same time.

2.

With a cantilever

equipment

runway beam extra care must be taken when operating

the beam SWL and at the extreme end of 3.

shall be used on the same runway beam at

at, or near,

the beam.

Do not: a.

Attach additional

steelwork

or suspend scaffold

beams. b.

Shock or side load runway beams.

Page 166 of 247

pipes, cables etc from runway

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

40.0 Lifting Points A ‘ L i f t i ng P o i nt ’ i s g e ne r i c t e r m f o r t he ‘ ce r t i f i e d’ po i nt ( s ) or a t t a chm e nt ( s ) o n a n i t e m o f pl a nt , by which it can

be safely lifted.

structural members and from

The term also applies

to points or attachments fixed

which a load can be suspended.

to

For example lifting lugs, lifting

eyes, trunnions, fabricated lifting plates, pad eyes.

40.1

Padeyes

Pad eyes are lifting eyes that have been at similar to be used for lifting purposes.

tached (welded or bolted) to a beam, structure or

Padeyes shall be identifiable at point of lo

cation with the padeye centrally positioned in a 20

cm x 20 cm painted square (minimum size). The square shall be painted with zebra striping. The striping must: 1.

Be at an angle 30-60 degrees

2.

Be 40-60 mm wide.

3.

Consist

of two contrasting

to the horizontal.

colours,

yellow and black.

WARNING: A PAD EYE IS DESIGNED AND CERTIFIED FOR VERTICAL LIFTS ONLY. HOWEVER, A SUITABLY SUPPORT WELDED PAD EYE (FIG 48) CAN BE USED FOR LIFTS AT ANGLES UP TO 45 PROVIDED THAT A RISK ASSESSMENT IS CARRIED OUT BY A ‘COMPETENT PERSON’. WHEN ASSESSING LOAD WEIGHT ON THE PAD EYE, INCLUDE WEIGHT OF LIFTING EQUIPMENT AND SLINGS, OR ADD 10% TO TOTAL IF WEIGHTS ARE ESTIMATED.

V i s u al l y c he ck t he state of the weld Zebra striping

Check condition of padeye in general and hole for elongation or damage Padeye identity and SWL (Padeye shall not be used if no identity

or

SW L is dis la ed !) Fig

48 Typical

Pad Eye Welded to Beam

Page 167 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

Fig 49 Pad Eye -

40.2

REV.1.0

Bolt-on Type

Bolt-on Pad Eyes

Bolted-on pad eye type lifting points suitable for the

fitting of shackles through which lifting

equipment can be attached are shown on Fig 49.

40.3

Pre-use Inspection

Check as follows: 1.

Check pad eye unique identification,

WLL, date of inspection

and next inspection

due

date are present and readable. 2.

Clean the pad eye and immediate

vicinity,

inspect

for damage, distortion

deterioration, if defects are found the pad eye must not be used. Report place a notice on the beam indicating that padeye must not be defect is rectified. Padeyes with flame cut holes are not

and defects and

used for lifting until suitable for lifting purposes

and therefore shall not be used.

40.4

Safe Use

Observe the following: 1.

A pad eye is designed

and certified

for vertical

lifts only. However,

a suitably

support

we l de d pad e y e ( F i g 4 8 ) ca n be u s e d f o r l i f t s at a ngl e s up t o 4 5 ° provided that a risk assessment is carried out by a ‘competent person’ and suitable de-rating is applied. 2.

Whenever

lifting

equipment

is attached

to a pad eye, a shackle

the pad eye and the equipment in the correct manner as shown in

Page 168 of 247

must be fitted between Fig 50.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

Fig 50 Fitting a Shackle to a

40.5

REV.1.0

Pad Eye

Other Types of Lifting Points

Other types of lifting points

that may be encountered on equipment to be lifted, and which can

be used if a risk assessment is

carried out, are listed below:

1.

Holes inherent

2.

Trunnions.

in the design,

3

Welded-on

4.

Links welded on to reinforcing

5.

All integrated

integral

suitable

for shackles.

pads for jacking points.

lifting

members in a concrete

points that are cast into concrete

structure. beams or blocks must be of a

propriety type, which have the necessary certification supplied. Under no circumstances shall high tensile reinforcing bar be used as or made into lifting points.

40.6

Additional

Lifting Points

If additional lifting points have been secured to a li

fting beam, the following points must also

be present: 1.

2.

Each additional

lifting

point shall be clearly

a.

Identification

(serial)

b.

Safe Working

Load at 0

c.

Inspection

and permanently

marked with:

number. °

to 90

°

.

date and next due date.

Tapped holes, when used to locate a lifting point (e.g. eye bolt), shall have the thread form and diameter permanently marked adjacent to each hole.

Page 169 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

When equipment

AND HOISTING

SMEP.EP200802258279

MANUAL

forms part of a larger assembly,

REV.1.0

a list of the assembled

individual weights, and the total assembled weight shall be given on

parts, their

a clearly visible

tally plate, e.g.:

Plant weights

Pump

2.6te

Motor

1.8te

Base Plate Total Assembly

0.9te 5.3te

A ny po s s i bl e l o a d s uppo r t i ng a r r a nge m ent ( e . g. a hol e i n t he be a m ) w hi ch ca nno t be us e d safely, and is accessible such that casual use could occur, shall be identified and t SUITABLE FOR LIFTING’.

Page 170 of 247

agged, ‘NOT

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

41.0 Spreader Beams and Lifting

REV.1.0

Frames

Spreader beams and lifting frames are often specially made to facilitate

a particular ‘lift’.

A c e r t i f i c at e of t e s t a nd e x a m i na t i o n s hal l be s u ppl i e d w i t h e a c h s pr e a de r be a m a nd a s s o ci a t e d equipment, or lifting fra

me. The certificate of test and

examination will refer to a

equipment, e.g. those covering the shackles, hooks etc, and the Non-destructive Examination (NDE) reports. Refer to Section 3.0

Page 171 of 247

ll associated

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

42.0 Manually-Operated Hoists 42.1

Ratchet Lever Blocks (Pull Lifts or Chain Lever Hoist)

A r a t c he t l e v e r bl o ck i s a l i ft i ng m a chi ne , w hi ch, t hr o u gh t he us e o f a ge a r box and br ak e mechanism, allows the user to raise heavy loads (commonly up to 6 t to the operating lever. Typical examples are shown capacities up to 15 tonne are manufactured.

onne) by applying a force

at Fig 51 ratchet lever

block with

Fig 51 Typical Ratchet Lever Block

Ratchet lever block can be operated at any angle, including upside down. They are available w i t h t w o t y pe s o f ch a i n i . e . s t a nda r d s hor t l i nk c ha i n and r o l l e r c hai n ( F i g 5 2 ) . L i nk cha i n models are the most popular as they are flexible and

easy to use whereas roller chain models

tend to be more rigid and the chains corrode and seize more readily. Some manufacturers of this type of ratchet lever block have a pawl release l the hoist pawl and allows the either direction.

ever that when manually operated release

load chain to be pulled freely through the machine, by hand, in

Fig 52 Ratchet Lever Block with Pawl

Page 172 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

WARNING: ON RATCHET LEVER-BLOCKS/PULL LIFTS WITH MANUAL RELEASE PAWL, THE PAWL MUST NOT BE DISENGAGED WHEN THERE IS A LO AD ON THE HOOK, OR THE LOAD WILL DROP. RATCHET LEVER-BLOCKS/PULL LIFTS THAT HAVE UN-COATED ALUMINIUM COMPONENTS IN THEIR CONSTRUCTION ARE UNSUITABLE FOR USE IN AN OFFSHORE ENVIRONMENT.

A n a dv a nt ag e w he n u s i ng a r a t c he t l ev e r bl o ck i ns t e ad o f a c hai n bl o ck i s t he ‘ dr aw n u p dimension' (closed height) where h

eadroom may be

limited.

A disadvantage with r

block is that to operate the ratchet lever block, the user must be

atchet lever

at the same level as the

suspension point, which could create a problem, if access to the hoist

suspension level is

restricted. Non-spark ratchet lever block are available for use in hazardous areas and pull lifts can also be supplied specially coated for use in an offshore envir suitable for sub-sea work but not all.

onment.

Most ratchet lever blocks are

Consult the manufacturers for confirm

ation of suitability

before using a ratchet lever block for sub-sea lifting. The design of ratchet lever block is such that a brake mechanism is used

to suspend the load.

This brake mechanism gives the lever hoist its versatility but use. The brake relies on the load tension f

also introduces limitations on its

or its operation, so the block requires a weight or

tension on the load chain before the brake mechanism will function and securely hold the load. Under very light load conditions, lever hoists have been known to of load on the brake. This has been a

pay out chain due to the lack

particular problem when, or immediately following,

changing the hoisting direction from up to down or vice versa. When planning a lifting operation using a lever hoist or selecting a lever hoist for

a lift, the light load

limitation of the

braking mechanism should be recognised and the hoist should not be used to lift less than 10% of t

a load that is

he stated working load limit for that hoist.

WARNING: THE RATCHET LEVER BLOCK/PULLIFT MACHINE IS DESIGNED FOR ONE-MAN OPERATION. DO NOT FIT A HANDLE EXTENSION, USE TWO-MAN OPERATION, OR USE ANY EXCESSIVE FORCE TO OPERATE THE HOIST. THE MINIMUM LOAD LIFTED SHOULD NEVER BE LESS THAN 10% OF THE SWL AT NO TIME DURING LIFTING OPERATIONS SHOULD THE WORKING LOAD LIMIT OF A RATCHET LEVER BLOCK BE EXCEEDED. A RATCHET LEVER BLOCK/PULLIFT MUST NOT BE IN A DYNAMIC LIFTING ARRANGEMENT WHERE THE LOAD ON THE BRAKE VARIES, E.G. AS THE LOAD GOES THROUGH THE SPLASH ZONE.

42.2

Pre-use

The following checks must be carried after ‘booking out’ from a rigging store and before use. If the ratchet lever block fails any one of the 1.

following checks it must be rejected:

Check hoist for unique identification,

WLL, date of inspection

and next inspection

date are present and readable. 2.

Where fitted,

check that the pawl operates

correctly,

in raising,

lowering

and 'pull through' (disengaged) modes of operation. When engaged the pawl gives a distinctive 'clicking' sound when the ratchet lever block is operated.

Page 173 of 247

(engaged)

due

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Check chain, load wheel and chain end stop. To prevent the end of the chain from passing through ratchet lever block, an end stop must be present on the f

ree end of the

load chain. 4.

Hang the ratchet

lever block on its suspension

'stop' and let it hang vertically free. The

hook and pull the load chain out to its

chain linkage must all appear to be in a

straight line, if the chain gives the appearance of having a ' block has been ov

erloaded whilst the chain

was twisted.

spiral' the ratchet lever There must be no d

amaged,

corroded or distorted components (Fig 53). 5.

Check for build-up

of dirt in the pocket wheel.

6.

Check correct operation

7.

Check the suspension

of selection

lever.

hook and load hook. Ensure hook safety latch functions

correctly

and the swivel operates without restriction. Check also for obvious opening-out, of either the load hook or the suspension hook. 8.

Check load chain for distortion,

9.

If the hoist has not been used for some time the load chain could be dry, spray with

corrosion

and any other form of damage.

light machine oil.

Fig 53

42.3

Ratchet

Lever Block Pre-use

Checks

Safe Use

Observe the following: 1.

On a hoist with a pawl release

lever, ensure that the pawl release

lever is in the

'engaged' position before operating the hoist (Fig 54). 2.

The pawl must not be disengaged

whilst there is a load on the hoist hook or the load

w i l l dr o p!

Page 174 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

3.

Do not use load chain for slinging

4.

Do not twist or knot the load chain.

SMEP.EP200802258279

MANUAL

purposes

REV.1.0

(Fig 55).

Fig 54 Ratchet Lever Block Pawl

Fig 55 Incorrect Use of

5.

Ensure that the suspension

Load Chain and Correct Slinging Method

point to which the hoist is to be attached

is approved

and is

of adequate capacity for the load to be lifted. 6.

Before applying a.

full load, to hoist, check that:

The load will not drop if hand lever is released. operating hand lever to take the weight of l

Check by selecting

‘Raise’

oad, and then releasing hold on

hand lever. b. 7

Select 'Lower'

When operating

and repeat (a) to check for slip/drop

the ratchet lever block ensure that the ratchet

smoothly and easily and

with a distinctive ratchet 'c

Page 175 of 247

when lowering. lever block operates

licking' sound.

If it requires

and

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

excessive force to operate the ratchet lever block, stop lifting operations and investigate, a ratchet lever block must always operate smoothly and easily; it is designed for one-man operation. Do not: a.

Use a handle extension.

b.

Apply excessive

c.

Operate

If operation of the hand 7.

force.

by two persons. lever is difficult

- something is wrong!

The ratchet lever block is much more versatile

than a chain block, as it can be used in

almost any orientation. It is important, however, that the free

end chain runs smoothly

through the block without ‘hanging up’. When the ratchet lever block is used in an inverted orientation it is possible for the free end chain to bunch up, jam temporarily then release unexpectedly if not fed through cleanly. It is t

herefore not recommended

that ratchet lever blocks be used fully inverted and that attention

is paid to how the

chain runs through the block when partly inverted. 8.

Where a ratchet lever block introduces

a single point failure

into a lifting

arrangement, the user must consider the use of static rigging or some other means to eliminate the potential single point failure. This

is particularly important if a load is to

be suspended on a ratchet lever block for an extended period. The need

for additional

backup rigging must be identified as part of the lift plan and risk

assessment. As an

alternative to static rigging, consideration can be given to the use of a suitably rated mechanical stopper fitted in place of the end stop t hat is capable of being moved up and down and attached to the free end chain such that it body of the ratchet lever block – like a movable end stop. Any

can be positioned close to the modification e.g. brake

friction material or chain end stop should be discussed with the

manufacturer. If the

brake mechanism fails the chain could only run through the hoist until the mechanical stopper contacts the ratchet lever block body, significantly limiting the distance the load can drop. 9.

When a load is removed from a ratchet lever block other than by the use of the ratchet lever block (e.g. by transfer of a load to a crane) the

brake mechanism will remain

locked together. Subsequent loading of the hoist (for example, by the t load on to the block from a crane) will result in the

ransferring of a

load being applied to a locked

brake mechanism – something manufacturers regard as bad practice, potentiall resulting in unexpected slippage as the block is then operated. If

y a ratchet lever block

has the load transferred off it (a common practice during sub-sea use) the block must be operated to unlock the brake and confirm the block is fully functional before a load is transferred back on to it. Alternatively the load can be l

anded (or suspended on

static rigging) by using the ratchet lever block before the transfer to the

other lifting

device. 10.

When using multiple

ratchet lever blocks,

capacity of at least 100% of the load.

each individual

block must be rated to a

If two or more ratchet lever blocks are used to

share the load during lifting operations, careful consideration of the operation is

Page 176 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

necessary as there is the potential to overload one

of the blocks (beyond the working

load limit) or under load one of the blocks (below 11.

If the application

requires

10% of the working load limit).

the load to be supported

for a significant

length of time

between the lifting and lowering operations, consideration should be given to using other equipment to sustain the load, as the block may corrode during the supporting period and be unsafe for the subsequent lifting or lowering part of the 12.

Contamination

operation.

of the brake lining can also cause the ratchet

lever block to fail. This

can be due to inappropriate cleaning practices, e.g. using a pressure washer or immersion in diesel, or because of in-water contamination.

42.4

After Use

Check as follows: 1.

Thoroughly

clean the ratchet lever block, remove any rubbish,

which may have become

attached to the chain preservative, and check generally for abnormalities. 2.

Secure lifting

chain to avoid chain lying on ground when hoist is hung in rigging

3.

Spray load hook and chain with light machine oil. Take care not to contaminate

store. clutch

mechanism. 4.

42.5 1.

Return the ratchet lever block to rigging

store and complete

‘returns’

procedures.

Ratchet Lever Blocks in an Offshore Sub-Sea Environment As with any item of lifting

equipment,

the ratchet

lever block will be specified

for a

maximum working load limit. This should not be exceeded during any lifting operation. It is important, therefore, when planning an underwater lifting operation that the load to be lifted on the block is

known or has been accurately estimated with an adequate

allowance for safety. The possible effects of additio

nal loading, such as friction,

seabed suction and buoyancy, should be included when the ratchet lever block is being selected for the lift. 2.

The ratchet lever block is intended

for straight

line static lifting.

If used in a dynamic

lifting arrangement, the changing loading may cause the block to fail or slip. As load goes through the splash zone the weight could come off the

the brake mechanism and

the chain could run out. Ratchet lever blocks are not suitable for use in over-board rigging and must not be used in a dynamic lifting application. 3.

During use, care must be taken to avoid needlessly

contaminating

the ratchet lever

block brake mechanism, such as by dragging it along the seabed.

4.

Extended periods in salt water and cyclic periods of immersion may accelerate the corrosion of the internal components in the ratchet lever block. Practices such as using ratchet lever blocks in the splash zone and continually subjecting them to salt and then air will accelerate corrosion and will affect the ability of

water the block to hold a

load in a short period of time. The prevention of accelerated corrosion leading to slippage/failure to hold the load can best be reduced by where the ratchet lever blocks are only used sub-sea once before being inspected, serviced and retested. Each ratchet lever block must only be submerged once and this immersion shall have a specified

Page 177 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

maximum time limit. A ratchet lever block must not be submerged a second time until it has been inspected, serviced and tested by a suitably qualified person.

42.6

Hand-Operated

Chain Blocks

A m a nua l cha i n ho i s t or cha i n bl o ck i s a l i f t i ng m a chi ne , w hi ch, t hr o u gh t he us e o f a ge a r bo x and brake mechanism, allows the user to raise heavy loads (capacities up to 50

tonnes) by

applying a force to the operating chain (hand chain). A typical chain block is

shown at Fig 56.

A C ha i n bl o c k pe r f o r m s a s i m i l ar f unct i o n t o t he r a t che t l e v e r bl o ck but ha s di s t i nct de s i gn differences: 1.

It has an endless

hand chain that operates

2.

It has a dedicated

load chain terminating

3.

A chain block has an automatic

brake mechanism

sustaining a load to the WLL of

the unit.

4.

the lifting

and lowering

functions.

with a safety hook. that is capable

A chain block has a ratchet wheel and a spring-loaded

pawl.

of arresting

and

Design is such that the

pawl will operate irrespective of wear in any part of the brake assembly, but may not operate effectively if the chain block is used out of vertical. 5.

It is not uncommon

for loads to be pulled horizontally

during rigging

operations,

however, it must be remembered that there is an increase loading effect on the chain block with horizontal movement of the load e.g. If a 1

tonne load is pulled 45 degrees

from the vertical, the load on the chain block will increase 1.5

Fig 56 Typical Chain

tonne.

Block Assembly

WARNING: CHAIN BLOCKS THAT HAVE UN-COATED ALUMINIUM COMPONENTS CONSTRUCTION ARE UNSUITABLE FOR USE IN AN OFFSHORE ENVIRONMENT.

Page 178 of 247

IN

THEIR

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

42.7

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Chain Block Usage Terminology

Commonly used chain block terminology is shown at Fig 57.

Fig 57 Chain

Block Terminology

A m a j o r co ns i de r a t i o n whe n s e l e cti ng a c hai n bl o ck i s t he ‘ dr aw n up di m e ns i o n' ( cl o s e d he i g ht ) due to the lack of headroom in offshore modules. This dimension varies w ith different manufacturers and different configurations.

42.8

Various Types of Chain Block

Standard chain blocks are supplied with swivelling top and bottom hooks for ease of attachment to suspension point and load. They can be hooked into along a runway beam or can be supplied `built-in' to a trolley to save clearance between runway beam and load is

a beam trolley for travelling headroom. Where

particularly restrictive, Ultra-low headroom trolley

hoists can be utilised.

42.9

Chain Block Safety Considerations

Chain blocks are primarily designed to operate vertically.

WARNING: THE PAWL OF A CHAIN BLOCK MAY NOT OPERATE EFFECTIVELY IF THE CHAIN BLOCK IS USED ONLY. ‘OUT OF VERTICAL’.

THUS CHAIN BLOCKS SHALL BE USED FOR VERTICAL LIFTS

IF A CHAIN BLOCK IS REQUIRED FOR USE ‘OUT OF VERTICAL’ THE PERSON IN CHARGE MUST BE CONSULTED, BEFORE SUCH A LIFT IS UNDERTAKEN. THE MINIMUM LOAD LIFTED SHOULD NEVER BE LESS THAN 10% OF THE SWL.

Page 179 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

THE CHAIN BLOCK IS DESIGNED FOR ONE-MAN OPERATION. DO NOT, USE TWO-MAN OPERATION, OR USE ANY EXCESSIVE FORCE TO OPERATE THE B LOCK. AT NO TIME DURING LIFTING OPERATIONS SHOULD THE WORKING LOAD LIMIT OF A CHAIN BLOCK BE EXCEEDED. A CHAIN BLOCK MUST NOT BE IN A DYNAMIC LIFTING ARRANGEMENT WHERE THE LOAD ON THE BRAKE VARIES, E.G. AS T HE LOAD GOES THROUGH THE SPLASH ZONE.

Non-spark chain blocks are available for use in hazardous areas, and they can also be supplied specially coated for use in an offshore environment. Most chain blocks are suitable for sub-sea wor

k. However, the brake material used in some

models will preclude sub-sea use and the manufacturer must be contacted for confirmation of suitability before a unit is used sub-sea.

42.10

Pre-use

The following checks must be carried out before use, if the chain blocks f

ail any one of the

following checks it must be rejected: 1.

Check chain block unique identification,

WLL, date of inspection

and next inspection

due date are present and readable (Fig 58). 2.

Check load chain for bent, stretched

or corroded

Fig 58 Chain

links.

Block Inspection

3.

Check hand and load chain pocket wheels are in good order and free from debris.

4.

Check body assembly

5.

Suspension

for damage.

and load hook safety latches must function

correctly

and swivels

operate

w i t ho ut r es t r i ct i o n. E ns ur e t ha t t he r e i s no o bv i o us ope ni ng- o ut o f t he ho o k ( s) .

Page 180 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

6.

AND HOISTING

Check load chain for distortion, attempt to straighten a

SMEP.EP200802258279

MANUAL

corrosion

distorted chain link.

REV.1.0

and any other form of damage. A distorted link may

Never

have been already

be damaged beyond repair and will be unfit for use. 7.

If the hoist has not been used for some time, the load chain may be dry and must be spray coated with light machine oil. Take care not to contaminate brake mechanism. The chain must not however, be over-lubricated as contamination of the hoist brake discs could result.

8.

If visible,

check ratchet pawl and ratchet wheel for correct operation,

distortion.

42.11

Similarly check for

damage and distortion to

damage and

any other visible mecha

nisms.

Safe Use

Observe the following: 1.

Do not use the chain block load chain for slinging

purposes,

to the way in which the chain block was designed to 2.

or make any modification

be used.

Ensure chain block load chain and the hand chain are of adequate

length for the

proposed lifting operation and the load hook has adequate range of lift. 3.

A chain block must be used for vertical

lifts only. The pawl of a chain block may not

operate correctly if the chain block is used out of the vertical. 4.

Do not attempt

to operate

the chain block beyond the maximum specified

possible to impose excessive load on the chain anchor when the

range.

It is

bottom hook is at its

lowest position. 5.

When using a hook suspended

chain block, ensure that the chain block hook can move

freely and unhindered in the eye of the attachment point. 6.

After attachment,

ensure that the load chain and hand chain hang freely and where a

bottom hook block is reeved with two falls ensure t

hat the block has not 'turned-over'

and the chain is not twisted. 7.

If the lifting

operation

involves

lifting

light loads with long load chains be aware that

the chain slack may be heavier than the load and cause a 'run-back' resulting in lowering the load.

Page 181 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Fig 59 Excessive Force on Chain Block Hand Chain

8.

Chain blocks are designed

9.

Do not allow dirt or grease to accumulate

for one-man operation,

without excessive

in the profiles

force.

of the hand or load chain

whe e l s . 10.

If the load chain 'jumps' the pocket wheel.

or does not operate

smoothly

it may not be sitting

This type of fault is more common on chain bloc

properly

falls where a load hook may have become ’turned over’, twisting the chain. If t the case the block

can be ‘flipped bac

in

ks with two or more his is

k’ to eliminate a twist in the

falls.

If after

flipping back, the load chain still ‘jumps’ the chain may have been stretched, or there is damage to the pocket wheel, in either case t he block must not be used. 11.

Listen for the 'clicking'

of the ratchet pawl during use. The absence

of the ratchet

'clicking' noise will indicate a malfunction in the chain block mechanism. 12.

Within its designed

operating

range, a chain block must operate

easily and smoothly

w i t h o ne pe r s o n o n t he ha nd cha i n. I f e x ce s s i v e f o r ce i s r e qui r e d o n t he ha nd cha i n t o lift a rated load, stop the operation and inve 13.

stigate.

Ensure that shock loads are not imposed on the chain block through too vigorous operation of the hand chain.

13.

If a chain block is accidentally

dropped,

it must not be used.

Return for

examination/overhaul. 14.

Where a chain block introduces

a single point failure

into a lifting

arrangement,

the

user must consider the use of static rigging or some other means to eliminate the potential single point failure. This is

particularly important if a load is to be

suspended on a chain block for an extended period. The need for additional backup rigging must be identified as part of the lift 15.

plan and risk assessment.

When using multiple

chain blocks,

each individual

at least 100% of the l

oad. If two or more chain blocks are used to share the load

block must be rated to a capacity

during lifting operations, careful consideration of the operation is necessary as there

Page 182 of 247

of

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

is the potential to overload one of the

If the application

requires

MANUAL

REV.1.0

blocks (beyond the working load limit) or under

load one of the blocks (below 10% of 16.

SMEP.EP200802258279

the working load limit).

the load to be supported

for a significant

length of time

between the lifting and lowering operations, consideration should be given to using other equipment to sustain the load, as the block may corrode during the supporting period and be unsafe for the subsequent lifting or lowering part of the 17.

Contamination

operation.

of the brake lining can also cause the chain block to fail. This can be

due to inappropriate cleaning practices, e.g. using

a pressure washer or immersion in

diesel, or because of in-water contamination.

42.12

After Use

Proceed as follows: 1.

After use, the chain block must be cleaned and inspected

following

used for Pre-use inspection. Do not jet wash with water as t

the same procedure

his will penetrate and

corrode internal mechanisms. Do not allow oil, grease or other substances to contaminate brake discs. A defective chain block must not be used, it must be sent

for

overhaul.

Fig 60 Chain Block

2.

Carefully

lubricate

a chain hoist; excessive

lubricant penetrating the brake, which could then a chain block, lubricate

Storage

or careless

3.

When storing

4.

Return chain block to rigging store and complete

lubrication

may lead to the

fail under load.

and 'wrap' the chains (Fig 60). ‘returns’

procedures.

CAUTION MANUAL OR POWERED OVERHEAD HOISTS SHALL NOT BE USED FOR LIFTING PERSONNEL

Page 183 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

42.13 1.

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Manual Chain Blocks in an Offshore Sub-Sea Environment As with any item of lifting

equipment,

the chain block will be specified

for a maximum

w o r k i ng l o ad l i m i t . T hi s s ho ul d no t be e x ce e de d dur i ng a ny l i f t i ng o pe r a t i o n. I t i s important, therefore, when planning an underwater lifting operation that the load to be lifted on the block is known or has

been accurately estimated with an adequate

allowance for safety. The possible effects of additio

nal loading, such as friction,

seabed suction and buoyancy, should be included when the chain block is being selected for the lift. 2.

The chain block is intended for straight line static lifting. If used in a dynamic lifting arrangement, the changing loading may cause the block to fail or slip. As the l oad goes through the splash zone the weight could come off the brake

mechanism and the

chain could run out. Manual chain blocks are not suitable for use in over-board rigging and must not be used in a dynamic lifting application. 3.

During use, care must be taken to avoid needlessly

contaminating

the chain block

brake mechanism. 4.

Extended

periods in salt water and cyclic periods of immersion

may accelerate

corrosion of the internal components in the ratchet lever block. Practices such as using ratchet lever blocks in the splash zone and continually subjecting them to salt and then air will accelerate corrosion and will affect the ability of

are only used sub-sea once before being inspected, serviced and retested. Each ratchet lever block must only be submerged once and this immersion shall have a specified maximum time limit. A ratchet lever block must not be submerged a second time until it

Page 184 of 247

water

the block to hold a

load in a short period of time. The prevention of accelerated corrosion leading to slippage/failure to hold the load can best be reduced by where the ratchet lever blocks

has been inspected, serviced and tested by a suitably qualified person.

the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

43.0 Powered Chain 43.1

Pneumatic

SMEP.EP200802258279

MANUAL

REV.1.0

Hoists Chain Hoists

Most powered chain hoists used in the hydrocarbon industry are pneumatically operated. The main safety feature built into this ty

pe of hoist is that the

“ON” position and require air pressure

for release.

brakes are spring-loaded to the

In the event there is a loss of pneumatic

power (e.g. a burst hose) the brake automatically applies to prevent the load safe).

Most hoists are also fitted with tri

The standard range of lift is 3 met requirement.

p devices to prevent

from falling (fail over-hoisting or over-

If a substantial increase is required, the manufac

turer must be consulted, as it

may be necessary to de-rate the hoist due to the excess weight of load c fitted with long load chains, a chain collector boxes

hain.

For chain hoists

can be fitted to the hoist.

The hoist control pendant or chains normally hang 1 metre above the l bottom hook.

lowering.

res but this can be increased to suit any specific

owest position of the

Pendant controls (with push buttons) are the preferred

option but can stick when

exposed to a contaminated air supply. Standard pneumatic hoists are usually supplied with a swivelling top and bottom hooks for ease of attachment to suspension point and load. They

can be hooked to a beam trolley for

travelling along a runway beam or can be supplied with a ‘built-in' trolley

to save headroom.

Pneumatically powered hoists are primarily designed to lift loads vertically but hook suspended blocks will work efficiently up to 45% off the

vertical.

WARNING: PNEUMATIC CHAIN HOISTS HOOKED TO, OR BUILT INTO TROLLEYS (OR COMBINED UNITS) MUST BE USED FOR VERTICAL LIFTS ONLY. PNEUMATIC CHAIN HOISTS ARE NOT SUITABLE FOR SUB-SEA WORK. Pneumatically powered hoists that have

un-coated aluminium components in their construction

are unsuitable for use in an offshore environment they can however be supplied specially coated for use in

an offshore environment.

Non-spark models ar

e available for use

in

hazardous areas.

43.2

Electrically

The main safety feature built into this ty

Powered Chain Hoists pe of hoist is that the

“ON” position and require power to release them. In the e

brakes are spring-loaded to the vent there is a loss of el

power, the brake automatically applies to prevent the load from falling (fail safe).

Page 185 of 247

ectrical

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 61 Typical Single

SMEP.EP200802258279

MANUAL

REV.1.0

Fall and Multi-fall Powered Chain Hoists

Electric chain hoists are available for single or three phase power supplies. Hoists are fitted with limit switches to prevent

The hoist control pendant normally hangs 1 metre above the hook.

Electric hoists usually have

suspension point and load.

also

over-hoisting or over-lowering.

lowest position of the bottom

swivelling top and bottom They can be hooked

hooks for ease of

into a beam trolley

attachment to

for travelling along a

runway beam or can be supplied with a `built-in' trolley to save headroom. Electric hoists are designed for vertical lifting. Electric hoists hooked or built into

trolleys (or

combined units) must be used for vertical lifts only.

43.3

Pre-use

Check the following: 1.

Check hoist unique identification, are present and readable.

WLL, date of inspection

2.

Check condition

3.

Check the load chain for any obvious signs of damage, wear, excessive

of the pendant

and next inspection

due date

control. corrosion,

cracks or distortion, signs of elongation. 4.

Ensure the load chain is adequately

5.

Check load hook for distortion

6.

Check that the unit operates

lubricated.

and ensure that the safety latch is operational. smoothly

in response

noise from the winch during operation. 7.

Check limit switches

8.

Check all electrical

function

correctly.

terminations

Page 186 of 247

to controls

and there is no abnormal

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

9.

Check load chain sprockets

10.

Examine

the general

SMEP.EP200802258279

MANUAL

REV.1.0

for wear, damage and debris.

structure

of the block for damage and that bolts and retaining

screws are tight and not corroded.

43.4

Safe Use

Observe the following 1.

Do not use the chain block load chain for slinging

purposes,

or make any modification

to the way in which the chain block was designed to

be used.

2.

Ensure chain block load chain is of adequate and the load hook has adequate range of lift.

length for the proposed

3.

A chain block must be used for vertical

4.

Do not attempt

to operate

lifting

operation

lifts only.

the chain block beyond the maximum specified

possible to impose excessive load on the chain anchor when the

range.

It is

bottom hook is at its

lowest position. 5.

When using a hook suspended

chain block, ensure that the chain block hook can move

freely and unhindered in the eye of the attachment point. 6.

After attachment,

ensure that the load chain hang freely and where a bottom hook

block is reeved with two falls ensure that the bl is not twisted. 7.

ock has not 'turned-over' and the chain

Do not allow dirt or grease to accumulate

in the profiles

of the load chain pocket

whe e l s . 8.

If the load chain 'jumps' or does not operate smoothly it may not be sitting properly in the pocket wheel. This type of fault is more common on chain bloc ks with two or more falls where a load hook may have become ’turned over’, twisting the chain. If t the case the block

can be ‘flipped bac

k’ to eliminate a twist in the

flipping back, the load chain still ‘jumps’ the chain may have been is damage to the pocket wheel, in either case t 9.

If after

stretched, or there

he block must not be used.

Ensure that shock loads are not imposed on the chain block.

Page 187 of 247

his is falls.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

44.0 Lifting and Pulling

SMEP.EP200802258279

MANUAL

REV.1.0

(Tirfor) Machines

Lifting and pulling machines are usually of the friction grip on cable type. A used is manufactured by Tirfor. This type of machine develops a pulling force on the l

type commonly oad rope

by a combination of alternate gripping and pulling (one grips while the other pulls) by of jaws. The jaw mechanisms are operated by an external hand l

two sets

ever. Most other lifting and

pulling machines that use a wire rope have a similar principle of operation. Tirfor rope hoists are available in several ranges the only range suitable in

SMEP is the TU

range. An example of a typical Tirfor lifting and pulling machines is

Fig 62 Typical Tirfor

44.1

shown at Fig 62.

Lifting and Pulling Machine

Tirfor Use - Safety Considerations

Tirfors’ will operate correctly only when used in conjunction with special load rope called 'Maxiflex'.

This rope is manufac

of the Tirfor machine.

tured in non-standard

sizes designed to suit the

gripping jaws

It is therefore important to use the correct design and size of r

the machine. A Tirfor will not operate safely or size Maxiflex wire rope is used in the machine.

ope for

efficiently if wire rope other than the correct

Tirfors are usually dual rated, with a WLL rating for lifting and

a separate (usually higher)

capacity rating for pulling. When selecting a machine, if both figures are present on the machine, in the interests of safety, selection must

be based on the (lower) WLL rating.

Shear pins fitted at the Tirfor hand lever mechanism ensure that

excessive leverage cannot be

applied to the machine mechanisms. Spare shear pins are usually kept in the hollow

shaft of

the operating lever stub.

WARNING: ONLY THOSE SHEAR PINS SUPPLIED BY THE MACHINE MANUFACTURER MUST BE USED. ONLY THE HAND LEVER SUPPLIED WITH THE MACHINE MUST BE USED. ONLY THE CORRECT SIZE ‘MAXIFLEX’ WIRE ROPE AS SUPPLIED BY THE MACHINE MANUFACTURER MUST BE USED. THE USE OF EQUIPMENT OTHER THAN THAT SUPPLIED BY THE MANUFACTURER WILL INVALIDATE CERTIFICATION AND MAY CAUSE THE MACHINE TO FAIL IN OPERATION.

44.2

Pre-use

The following checks must be carried out before use:

Page 188 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

1.

AND HOISTING

Check Tirfor unique identification,

SMEP.EP200802258279

MANUAL

REV.1.0

WLL, date of inspection

and next inspection

due

date are present and readable. 2.

Generally

check the machine and inspect

for corrosion,

deterioration

and any other

form of damage. 3.

Tirfors

must only be operated

with the correct size 'Maxiflex'

not operate safely or efficiently if any other form of 4.

Check that the shear pins are in position

wire rope. A Tirfor will

wire rope is used. in the operating

lever/spindle

and that spare

shear pins are present in the hollow shaft of the operating lever stub. Only shear pins supplied by the manufacturer shall be used in the operating lever of the Tirfor (Fig 63). The shear pin is intended t

o fail and protect the Tirfor mechanisms from overload

in the event of excessive force being applied to t

he operating lever.

Fig 63 Tirfor Shear Pins

Page 189 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

5.

Check condition

6.

Check for wear in the jaws as follows: a.

MANUAL

REV.1.0

of Tirfor anchor point.

With no rope fitted (and lever in 'released' case the position of the rope release

b.

SMEP.EP200802258279

position)

mark on the machine

lever.

Insert the correct rope into the machine and move the rope release 'jaws closed' position and make a second mark at the positi

lever to the

on of the rope

release lever. c.

The distance stated limits.

between

d.

If the distance

the two marks must not be less than the manufactures

between

the two marks is less than that stated by the

manufacturer, wear on the rope jaws is indicated and the machine must not be used. NOTE:

7.

REDUCTION IN ROPE DIAMETER MAY ALSO INFLUENCE THE ABOVE MEASUREMENTS.

Thoroughly

check the 'Maxiflex'

wire rope as follows:

a.

Ensure that the rope has no kinks. A kinked load rope will cause the machine

b.

Wipe the rope clean before fitting

to malfunction.

examine the rope for 8.

it to the machine

wear and damage.

and at the same time

A damaged rope m

ust not be used.

Ensure that the machine is well lubricated. To lubricate both jaws of the machine the reversing lever in a central position and using oil can 'squirt' medium gear oil into the mechanism, through the slot in the top of

place

the casing, in front of and behind the

reversing lever.

44.3

Inserting

the Maxiflex Load Rope into the Tirfor Machine

A f t e r i ns pe ct i o n i ns e r t t he ' M a x i f l e x ' l o ad r o pe i nt o t he ' T i r f or ' a s f ol l o w s : 1.

Operate

"Rope Release"

mechanism

2.

Insert the fused and tapered

to open jaws in machine.

end of the load rope into the guide hole at the opposite

end to the anchor and push the rope through the machine until it

emerges from the

guide hole at the anchor end. 3.

Pull the load rope through the machine until a working length is obtained.

4.

Operate "Rope Release"

44.4

lever to close machine jaws onto rope.

Safe Use

Observe the following: 1.

Do not allow the load rope to become kinked especially

when uncoiling

for use and

whe n r e co i l i ng a f t e r us e ; e v e n a s l i g ht k i nk ca n ca us e m a chi ne m a l f unct i o n. 2.

Use only the hand lever provided

for the machine.

Page 190 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

3.

AND HOISTING

Ensure that the machine

is anchored

SMEP.EP200802258279

MANUAL

to a certified

REV.1.0

attachment

point of adequate

capacity. 4.

The 'Maxiflex'

wire rope must not be used as a sling, it will be damaged and rendered

unfit for use in the Tirfor. 5.

Do not allow the load rope to rotate.

This will unlay the strands

and render the rope

unfit for further use. CAUTION:

IF THE TIRFOR MACHINE FAILS MECHANICALLY DURING A LIFTING OPERATION, OR AN OPERATION WHERE THE LOAD IS BEING MOVED ALONG AN INCLINE, THE LOAD ROPE (AND HENCE THE LOAD) MAY NOT BE HELD.

44.5

After Use

Proceed as follows: 1.

If a machine

has become contaminated

during use it can be dipped in paraffin,

alternative, suitable cleaning fluid, and shaken to d islodge foreign matter. and re-lubricate by applying medium gear oil through the top slot as previously

or Dry off

described. 2.

For longer life and better performance, grease when it appears ‘dry’.

the wire rope must be lubricated

with acid-free

3.

Return the machine and rope (together)

to the rigging store and complete

the ‘returns’

procedure.

Page 191 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

45.0 Snatch Blocks Snatch blocks are used when it is necessary to c

hange the direction of the pull on a line.

snatch block can be a single or multi-sheave block that has an opening side pl rope to be placed over the sheave pulley, thus eliminating the through the block.

A

ate to allow a need for the rope to be threaded

This is particularly useful where end fittings would hinder /

prevent a rope

from being threaded through a block. Where an anchored snatch block is used to change the direction of a line pull, the resultant stress the 'load' line and the 'pull'

on the anchor point depends on the angle between

(see Fig 64). This shall

be borne in mind when selecting a snatch

block and a snatch block anchor point.

45.1

Wire rope Pulley Blocks

Pulley blocks or sheave blocks are available in the form of single

sheave or multi-sheave with a

choice of head fittings, the most popular being swivel shackle or swivel oval The main function of a single sheave block is rope.

eye (Fig 64).

to change the direction of the hoisting or pulling

Multi-sheave blocks, when rigged in the norm

pull required on the lead rope to lift a load.

ally used ‘advantage’ mode, reduce the The pull required on the lead rope reduc

es as the

number of falls (sheaves) increases.

Fig 64 Single and

Multi-fall Sheave Blocks

The two main types of block available are the multi-sheave block and single

sheave block.

Pulley blocks or sheave blocks are available in various capacities, and with or without beckets

NOTE:

THIS SECTION DOES NOT APPLY TO DRILLING DERRICK BLOCK SHEAVES.

45.2

Pre-use

Check as follows: 1.

Check snatch block unique identification,

WLL, date of inspection

and next inspection

due date are present and readable. 2.

Check that all moving parts operate freely.

3.

Check generally

for wear, damage, distortion

use the block if any defects are found.

Page 192 of 247

and any other damage (Fig 65).

Do not

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

Fig 65

45.3

SMEP.EP200802258279

MANUAL

REV.1.0

Snatch Block Insp ection

Safe Use

Observe the following: 1.

Ensure that the sheave centre pin remains well lubricated,

2.

Ensure that rope(s) do not become twisted

3.

Confirm

that the structure

but do not over-lubricate.

when reeving.

to which the snatch block will be anchored

is of adequate

strength. 4.

Check that the clearance

between

sheave(s)

and check plates,

small enough that there is no danger or the rope

the clearance

shall be

slipping between the sheave and side

plates of the block. 5.

Where an anchored

snatch block is used to change the direction

of a line pull, the

resultant stress on the anchor depends on the angle bet ween the 'load' line and the 'pull' (Fig 66). This must be considered when determining the strength of the snatch block anchor point.

Page 193 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

Fig 66 Load On

45.4

SMEP.EP200802258279

REV.1.0

Snatch Block Anchor

After Use

Proceed as follows: 1.

Clean the snatch block, and check for damage and deterioration,

in same manner as

for pre-use inspection. 2.

Lubricate

3.

Return snatch block to rigging store and complete

block centre pin and swivel(s).

Page 194 of 247

‘returns’

procedure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

46.0 Winches W i nche s a r e de s i gne d t o be o pe r a t e d o nl y w he n t he y a r e a nc ho r e d t o a f i r m f o unda t i o n, e . g. floor or wall mounting. A typical manually operated winch and a pneumatically powered winch are shown on Fig 67. The majority of utility

winches used on (spark free) offshore platforms

are pneumatically powered. Most Winches (manual and powered) have two speeds of operation. Loads must never be l

ifted

in high gear; high gear must be used only for rapid movement when unloading/lowering with no load, or light load on the hook.

PNEUMATIC

MANUALLY OPERATED

Fig 67 Manually Operated and Powered Winches

W i nch s e l e ct i o n i s u s ua l l y de t e r m i ne d by t he i r ‘ l i ne pu l l ’ . H o we v e r , t he m a j o r i t y o f manufacturers' line pull ratings are based on ‘half drum’ performance and this line pull decreases as the drum fills up (see Fig 68).

FULL DRUM

MAX. SPEED MIN. PULL

HALF DRUM

MED. SPEED MED. PULL

1st WRAP

MIN. SPEED MAX. PULL Fig 68 Drum Capacity and Line NOTE:

Pull Diagram

HALF DRUM RATING ESTABLISHES AVERAGE PERFORMANCE ONLY.

THIS MUST

NOT BE FULL CONFUSED WITH WIRE WHICH IS APPROXIMATELY ONLY 36% OF DRUM STORAGE ATROPE THIS CAPACITY, POINT.

Page 195 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

A f ur t he r co ns i de r a t i o n w he n s e l e ct i ng a w i nch f o r a pa r t i cul ar o pe r a t i o n i s i t s dr u m c a pa ci t y i.e. how much wire rope is required for the particular operation as this can often lead to a higher capacity winch being required due to loss of line pull. A l l pow e r e d wi nche s m us t ha v e a f a i l -s a f e br ak i ng s y s t e m , i . e . s pr i ng a ppl i e d a nd ( pne u m a t i c) power released. The design must be such that when the neutral position, or in the event of an air

main control lever is returned to the

pressure supply failure, the winch brake will

automatically apply.

46.1

Man-riding

Winches

W i nche s t ha t ar e us e d f o r ‘ l i f t i ng pe r s o ns ’ m u s t co m pl y w i t h L O L E R , R e gu l at i o n ( 5 ) ( 1 ) ( a ) t o ( d) or ASME B30.23. Equipment used for lifting people shall have a its strength of at least

safety coefficient relating to

twice that required for general lifting operations.

A l l wi nc he s s ui t a bl e f o r m a n- r i di ng o pe r a t i o ns m us t ha v e a pe r m ane nt l y a nd cl e a r l y m a r k e d, prominently displayed, rating plate indicating "SUITABLE FOR MAN-RIDING" or "SUITABLE FOR LIFTING PERSONNEL".

Any winch not so ma

rked must NOT b

e used for lifting personnel. Only

w i nche s t hat ha v e be e n de s i gne d s pe ci f i ca l l y f o r m a n r i di ng c an be u s e d o n SM E P o pe r at i o ns . The winch-operating lever shall automatically be returned to neutral when released and the automatic brake

shall be applied.

The automatic brake

and/or the control system. A winch used for the lifting and

shall also apply on loss of po

wer

lowering of personnel must

incorporate a secondary braking system, which is independent of both the automatic brake and the primary power source.

This brake shall be of a simple design and preferably man

operation (Fig 69). The design of the winch

ual in

controls shall prevent inadvertent operation.

Automatic Brake

Manual Brake

Fig 69 Dual Brake System on Winches

W i nche s us e d f o r l i f t i ng pe r s o nne l s ha l l no t be f i t t e d w i t h cl ut c he s o r a ny ot he r m e a ns o f disengaging the drive s

ystem.

The winch drum

and other moving

guarded. The guards must not inhibit the operator to view the spooling of t drum.

parts must be suitably he rope onto/off the

A c l e ar l y v i s i bl e e m e r g e nc y s t op de v i c e s ha l l be l o ca t e d a dj a ce nt t o and w i t hi n e as y r e a ch o f the operator's control station.

Page 196 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

The main hoist cable and attachments shall have a

REV.1.0

minimum factor of safety of 8:1 relative to

the hauling load. The winch must be of adequate capacity to raise and lower the lo

ad at a speed not in excess of

10m/min and shall incorporate a load limiting device, which prevents loading the system in excess of the rated capacity (WLL) plus 50% or being crushed.

other loading, which will prevent the passenger

The winch shall also include an automatic cut-ou

t device, which will shut off

the primary winch power supply when the unit reaches the upper limit of its travel. The capacity of the winch must be based on the line

rated

pull on the top layer, with an 8:1 f

actor of

safety. Devices shall be incorporated in the winch system, which prevent the personnel

carrier from

over-riding, under-riding and over speeding. The winch must have adequate capacity to handle the following load l w r ap o f r o pe s po ol e d on t he dr um : 1.

Nominal

2.

The tare weight of the basket/carrier.

3.

The rope weight and the friction

ine condition with one

weight of the persons carried.

effects

of the sheaves etc,

W e i g ht o f a ddi t i o na l pe r s o nne l a nd e qu i pm e nt a s m ay be ne e de d t o pe r f o r m e m e r ge ncy operations. The sum of these weights shall

include the factors of safety.

The winch shall be capable of raising/lowering the carrier in a controlled manner in the event of an emergency or loss of power to the drive and/or control system. Means shall be provided to prevent rope entanglement, undue wear and to ensure the remains captive at all times around the sheaves and at the winch drum. The brake holding capacity shall be less than that

rope

generated by the minimum breaking load of

the rope and greater than that generated by the maximum line forces due to

the carrier,

passengers etc. The rope shall be spooled on to

the winch drum in a disciplined manner; i.e. bunching of the

rope is not permitted. The design of the system shall

ensure that the weight of the rope on

sheave system is never greater than the minimum weight on the carrying side of the

the winch side of the sheaves

system. NOTE:

THE DESIGN AND OPERATIONAL ASPECTS OF THE WINCH SYSTEM SHALL BE CONFIRMED BY A HAZARD AND FMEA CARRIED OUT BY THE WINCH SUPPLIER. THE ANALYSIS SHALL INCLUDE THE IDENTIFICATION OF SAFETY CRITICAL ELEMENTS ON WHICH REGULAR INSPECTION, MAINTENANCE AND FUNCTION TESTING IS REQUIRED TO BE CARRIED OUT BY THE OPERATOR.

46.2 46.2.1

Hand-Operated

Winches

Pre-use

Check as follows:

Page 197 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

1.

AND HOISTING

Check winch unique identification,

SMEP.EP200802258279

MANUAL

REV.1.0

WLL, date of inspection

and next inspection

due

date are present and readable. 2.

Check all securing

bolts are secure.

Make sure the winch rope is of.

3.

a.

The correct size for the winch

b.

The correct length.

c. Correctly anchored, and does not overfill Check the winch brake and ensure that: a.

The winch is in the correct gear.

b.

The driving pinion is fully engaged.

c.

The pinion drive-locking

d.

The handles

e.

the drum.

device is secure.

are fully engaged.

Check the operation

of the pawl, it must engage completely

with the ratchet

whe e l .

46.3

Safe Use

Observe the following: 1.

Never attempt

2.

When lowering

3.

Check operation

to lift a load in excess of the winch WLL. a load, use slow speed gearing. of brake for slippage;

keep water/oil

and dirt away from brake

linings. 4.

Some winches have two speeds of operation gear.

High gear mu st only be used for

46.3 46.3.1

and loads must never be lifted in high

rapid movement

when unloaded.

Electric or Air Driven Winches Pre-use

Check the following: 1.

Check hoist unique identification,

WLL, date of inspection

and next inspection

due date

are present and readable. 2.

Inspect winch rope for obvious signs of damage, kinking,

3.

Check winch drum for correct spooling

4.

for condition and security. Check brake bands for wear or contamination.

5.

Check all brake linkages

6.

Check condition

for operation

of operating

wear, and corrosion.

of wire rope, if practicable

check rope anchor

and condition.

lever, it must return to Neutral when released

Page 198 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

7.

Check all fluid levels - top-up if required.

8.

Check load hook(s)

for distortion

SMEP.EP200802258279

REV.1.0

and ensure that the safety latch is operational.

(If

fitted). 9.

Check delivery

10.

Check that the unit operates

air pressure,

all hoses and connections smoothly

in response

for air leaks.

to controls

and there is no abnormal

noise from the winch during operation. 11.

Check all electrical

12.

Examine

terminations

the general

structure

or air supply connections

as appropriate.

of the winch for damage and that bolts and retaining

screws are tight and not corroded. 13.

Check condition

46.4

of the exhaust.

Safe Use

Observe the following: 1.

Ensure all controls

are clearly marked.

2.

Do not stand in line with the wire rope cable when it is under load or being lowered

or

raised. 3.

Winch operators

must be wearing

safety goggles and safety gloves.

4.

When paying out wire rope, ensure that personnel

5.

Do not stand on the winch machinery.

are kept clear of the loose rope.

6.

Do not hand wind a wire rope on to a drum.

7.

Do not work too close to the drum, the wire rope could ‘Jump’ and trap hands or

8.

Do not operate

9.

Do not cross the wire rope on the drum; it will crush or flatten

clothing. a winch until all protective

guards and covers are fitted. the rope, rendering

the

rope unserviceable. 10.

Ensure a fleet angle of ¼º - 1¼º for grooved drums and 1 º - 3º for plain dr ums is not exceeded.

Page 199 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

47.0 Hydraulic Jacks, Rams

SMEP.EP200802258279

MANUAL

REV.1.0

and Pumps

Hydraulic lifting equipment is available in two basic arrangements: 1.

A combined

unit consisting

ram/plunger

and cylinder

assembly

with an integral

pump

unit (see Fig 70(a)) 2.

A set consisting

of a separate

ram and pump interconnected

by a high pressure

hose

(see Fig 70(b)) The operational situation will determine selection of hydraulic jack type.

(a)

(b) Fig 70 Hydraulic Jack Units

The jack must be marked with its identification number and WLL and in t the WLL, which may be lifted on

he case of a toe-jack,

the toe, must be marked on the jack in addition

to WLL of the

jack head.

For environments where there is a lack of space to insert a jack, some models of jack (with extended bases) can be fitted with a claw attachment. The use of a claw attachment (Fig 71) reduces the capacity of the jack by approximately 40% of its srcinal capacity refer to manufacturers manual.

Fig 71 Claw Attachment Fitted to Hydraulic Jack

A s a n al t e r na t i v e t o a j a ck w i t h a cl aw t he r e ar e l o w- he a dr o o m r a m s k no w n a s panc ak e r a m s or pad jacks.

However the major drawbac

k with this type of jack is its very limited stroke.

Some designs of jack have rams with locking collars, which can be adjusted to creep when a load must be sustained at a particular height (see Fi

Page 200 of 247

prevent ram g 72).

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

Fig 72 Hydraulic Ram with

REV.1.0

Locking Collar

A s a n addi t i o na l s a f e t y m ea s u r e , a l o ck o f f s a f e t y v al v e ca n be f i t t e d t o t he r am t o m a i nt a i n pressure in the event of a hose failure.

Standard rams and jacks are not suitable for sub-sea work; specialised jacking equipment is required for sub sea work.

47.1

Pre-use

Check the following: 1.

Check jack unique identification,

WLL, date of inspection

and next inspection

due date

are present and readable. 2.

In the case of a toe-jack,

the WLL, which may be lifted on the toe, must be marked on

the jack as well as the WLL

47.2

of the head.

Ratchet Jacks

1.

Check for wear on the jack pawls.

2.

Check for wear at the linkages

3.

Check correct functioning

4. 4.

Ensure the rack is greased, Ensure all

47.3

bushes and

surfaces.

except on the teeth side; keep the teeth clean.

bearings are

Hydraulic

and on the sliding

of the whole mechanism.

clean and

adequately lubricated.

Jacks

1.

Check for fluid leakage;

do not use the jack if there is evidence

2.

Check hydraulic

3.

Check for bends and/or cracks in the foot or body.

4.

If the jack is of the separate

of fluid leaks.

fluid level.

pump type, check condition

connectors.

Page 201 of 247

of connecting

hose and hose

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

47.4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Safe Use

The following checks apply cover mechanical 1. Apply the load centrally capacity.

and hydraulic jack assemblies:

and in line with the jack/ram

2.

Fully support the base of the jack/ram.

3.

Stabilise

4.

Ensure that a jack with a claw attachment

5

Screw down locking collar (where fitted)

6.

Open hydraulic

release

7.

Check pressure

rating of hoses/gauges/fittings

8.

Keep the ram/piston

9.

Fully retract ram before disconnecting

10.

Do not go under a load supported

the base of pump unit to prevent overturning

and do not exceed rated

when pumping.

has an extended

base.

when the load is to be sustained.

valve slowly when lowering

load.

etc.

clean. hydraulic

hose(s).

solely by jacks.

A load must not be left supported

entirely by jacks. 11.

When a load is being jacked up, it must be followed packing, so that in the event of the

closely

by the insertion

of suitable

jack slipping or failing, the load will only have a

short distance to fall onto the packing. 12.

Do not drop loads onto jacks/rams.

13.

When using jack claw attachments, stated in the

47.5 1.

it shall not exceed 40% of the jack capacity,

or

manufacturers operational manual.

After Use When not in use keep ram under a small pressure

so that the leather

cup washers

remain expanded. 2.

Check jack as for pre-use

checks and return to rigging store and complete

procedure.

Page 202 of 247

‘returns’

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

48.0 Overheard Cranes Overhead cranes are available with two basic bridge designs i.e. single girder and double girder. With single girder construction, the hoist unit is suspended from a trolley mounted on the lower flange to provide “cross travel” (see Fig

73).

A t t e nt i o n i s dr a w n t o She l l ’ s g l o bal s t a nda r d on l i f t i ng and ho i s t i ng EP2005-0264-G01 5 page 16)

Fig 73 Overhead Crane -

Single Girder Type

Fig 74 shows the double girder type of overhead crane where the crab unit travels mounted on top of the girders or between them with the

on rails

crab wheels running on the lower

inside flanges.

Fig 74 Overhead Crane - Double Girder Type

Double girder cranes have an advantage over single girder cranes in that they have reduced headroom and increased height of lift due to the decreased beam depths and the raise the hook up between the beams. In both t by means of carriages fitted at each end of and at

48.1

ability to

ypes of overhead crane, long travel is obtained right angles to the cross girder(s).

Hoisting and Travelling

Units

The hoisting unit can either be:

Page 203 of 247

(section

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

under-slung

trolley

SMEP.EP200802258279

MANUAL

hoist (fitted

REV.1.0

1.

A standard

2.

A crab unit mounted between or on top of the bridge girders (for wire rope only). The

with either wire rope or chain) or,

bridge being compatible with the width of the building or module. The hoisting unit and travelling unit, may be electrically, pneumatically or hydraulically powered -

or manually

powered

(through hand

chains).

A combination

of powered

and

manual operation is also possible.

Most powered units have either single speed or dual speed options but all are fitted with over hoist limits as a safety feature. Additional safety features that are fitted to most u nits are cross travel and long travel brakes/limit switches, and in some applications, anti-collision limit switches if more than one crane operates on the same

rails.

A l l o f fs ho r e ov e r he a d cr a ne s m us t be co at e d f o r us e i n a m a r i ne e nv i r o nm e nt .

A l l e l e ct r i c al l y po w er e d cr a ne s m us t be r a t e d a ppr o pr i a t e t o t he z o ne i n w hi c h t he y ar e f i t t e d.

CAUTION MANUAL OR POWERED OVERHEAD TRAVELLING CRANES SHALL NOT BE USED FOR LIFTING PERSONNEL

48.2 1.

Pre Use Check overhead

travelling

crane unique identification,

WLL, date of inspection

and

next inspection due date are present and readable. 2.

Ensure a competent Signal Person is nominated. than three people are available for the lift, the Si

3.

Ensure a competent

Except in circumstances where fewer gnal Person shall serve that role only

and shall not simultaneously act as a rigger. rigger is used to act as a load handler

for lifting

operations.

Except in circumstances where fewer than three people are available for the lift, riggers shall serve that role only and shall not

simultaneously act as the Designated

Signal Person. 4.

In circumstances

where fewer than three people (competent

operator,

signal person,

and rigger) are available to conduct a lift, a JSA must be carried out. 5.

Discuss

the circumstances

of the lifts with all personnel

involved

but not limited to the operator, signal person, and riggers before any lift 6.

Obtain all pertinent

information

(weights,

hazardous

with the lift, including is made.

material,

etc.), prior to

commencing lifting operations. 7.

Crane load limits must be adhered to at all times.

8.

The competent operator for overhead cranes must know the weight of the load and assure that it is within acceptable limits of the crane before lifting.

9.

The competent

operator

for overhead

cranes, in conjunction

responsible for ensuring that all loads are properly rigged before lifting.

Page 204 of 247

with the rigger, is

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

10.

Before starting

AND HOISTING

SMEP.EP200802258279

MANUAL

the crane, the competent

REV.1.0

overhead

crane operator

must do the

following: a.

Conduct and document

b.

Ensure all controls

c.

Ensure all personnel

48.3

the pre-use inspection.

are in the "off" or "neutral"

position.

are in the clear of the load.

Safe Use

W hi l e us i ng t he cr a ne , t he co m pe t e nt o pe r a t o r f o r o v e r he a d cr a ne s s ha l l do a t l ea s t t he following to assure clear 1.

communications are maintained:

Only respond to signals

from the Signal Person, (but must obey an emergency

signal

regardless of who gives it). 2.

Ensure communication

3.

Ensure that signals or visually.

is established

& maintained

with the Signal Person.

from the signal person are always understandable

The operator must not

respond unless signals ar

either verbally

e clearly understood.

Ensure that the signal person is in clear view, when appointed

(unless during blind

lifting operations). 4.

Ensure that the signal person can clearly

see the load, crane, personnel

and area of

operation (unless during blind lifting operations). 5.

Ensure proper and correct use of standard

hand signals.

the situation requires it and ensure that the desi

Develop

special

signals

when

gnated signal person and overhead

crane operator understand and agree with the special signals. 6.

Conduct load movement

7.

The Operator

only on instruction

for overhead

from the Signal Person.

cranes shall do at least the following

to assure safe

handling of loads: a.

Be at the crane controls

b.

Keep loads in sight at all times until the load and tag line (where applicable)

at all times while a load is suspended

c.

Ensure the load is attached

have safely left the ground (unless during blind lifting operations). to the hook by means of slings or other suitable

devices. The latch must be closed to secure loose slings. d.

Ensure the hoist rope is not wrapped around the load.

e.

Properly

f.

Take care when travelling

use slings in accordance

with section 15.9, 15.10 and 15.11.

the crane to minimize

the swinging

pendulum

of the hook and suspended load. g.

Ensure all personnel

h.

Always maintain condition.

are clear of the lifting

operation.

at least two wraps on the hoist drum in any operating

Page 205 of 247

action

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

48.3.1

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Do Not:

1.

Travel the crane at excessive

2.

Travel the crane into end stops or other crane except at very low speed

speed

3.

Use the crane for dragging

loads unless properly

rigged for a vertical

pull that does

not exceed the rated capacity 4.

Hoist, lower or travel the load while personnel

are on the load.

5. Hoist a load over personnel. A ddi t i o na l l y , t ag l i ne s m a y be u s e d at t he di s cr e t i o n o f t he o pe r a t o r a nd/ o r as de t e r m i ne d by a JHA where appropriate. When used, tag lines they shall 2 metres. Riggers must never stand under a load to grasp tag li

Page 206 of 247

have a minimum extended length of nes.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

49.0 Vehicle Loading Cranes (e.g. H

REV.1.0

iab Crane)

A v e hi c l e -l oa di ng c r a ne i s a c r a ne , w hi c h i s u s e d t o l o a d a nd u nl o a d o w n ca r go a boa r d t he v e hi cl e s . T hi s cr a ne c an a l s o be us e d fo r ge ne r a l l i f t i ng o pe r a t i o ns i f ce r t i f i e d, r e f e r t o t he crane’s capacity charts. V e hi c l e - l o a di ng cr a ne s c a n be us e d f o r t he f o l l o w i ng: 1.

The crane is assembled

on a device that is designed

and constructed

for the

transportation of loads. 2.

The crane is assembled of loads.

on a device that has not been fitted out for the transportation

The crane is also used for other lifti

ng operations other than loading and unloading of it’s own

v e hi cl e .

49.1 1.

Pre Use Check vehicle

loading

crane unique identification,

SWL, date of inspection

and next

inspection due date are present and readable. 2.

Ensure a competent

banksman

and rigger are nominated.

Banksman act simultaneously as a 3.

Check for fluid leakage;

It is acceptable

to have the

rigger.

do not use the crane if there is evidence

of fluid leaks.

Check hydraulic fluid level.

49.2 1.

Safe Use The vehicle-loading

crane must be used with the outriggers

in the maximum extended

position and conform to the capacity lift plan and manufacturer’s instructions. 2.

Outriggers must be installed at an equal maximum distance. When insufficient support, blocking are to be used. Blocking must be made of sound and strong material.

3.

The vehicle-loading

crane shall only be used within the radii indicated

surface

and in

conformance with the capacity chart. 4.

Vehicle loading

cranes with a working

load of more than 1000kg shall be provide

with

a Load Moment safety device. 5.

Vehicle loading

cranes with a working load of less than 1000kg may be provide

with a

hydraulic overpressure safety device. 6.

An audible

signal shall be installed

with cranes of a reach of 12M and on cranes with

a remote control. NOTE:

IT IS A REQUIREMENT THAT ALL VEHICLE LOADING CRANES WITH OUTRIGGERS SHALL USE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE.

Page 207 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

50.0 Flexible Intermediate Bulk Co 50.1

ntainers (FIBC)

Lifting of filled FIBCs

Flexible intermediate bulk containers are used for the bulk transport of non-hazardous powder and granular material. They are designed to be lifted vertically from above.

50.2

Pre-Use

Before lifting, FIBCs must be thoroughly examined for damage to stitching/gluing/welding and for surface abrasion, cuts, tears or any other damage to the bag. Particular attention must be paid to the lifting loops. The 1.

Abrasion;

examination shall look for signs of the f

the effects

of abrasion

are variable,

ollowing:

but some loss in strength

is to be

expected. In extreme cases, the fabric becomes so worn that the outer yarns

of the

w e av e a r e s e v e r e d. O n l i f t i ng l o o ps , l o ca l i z e d a r ea s o f a br a s i o n m a y be pr e s e nt caused by handling equipment with sharp edges, and these areas may result in a serious loss in strength. 2.

Cuts, contusions

cuts, particularly

in the lifting

loops or devices,

may result in a

serious loss of strength. 3.

Ultra violet degradation

and/or chemical

attack.

These may be indicated

softening of the material (sometimes with discoloration), so that

by the

the outer surface may

be rubbed off or plucked off, and in extreme cases, the outer surface may become powdered. Ensure the lifting loops are positioned according to the manufacturer's instructions. Inspect the hooks, bars or fork lift arms employed for lifting

to ensure that they have rounded

edges with a radius greater than the diameter or thickness of the

suspension of the FIBC

and/or be protected by wrapping. The rounded edges shall have a minimum radius of 5 mm.

50.3

Repair of FIBCs

Repairs must never be carried out on damaged FIBC's. Damaged FIBC's must be effectively destroyed.

50.4

How to use FIBCs

The approved number of trips for a FIBC must not be exceeded i.e. single

trip bags must only

be used once. FIBCs for hazardous materials must meet the special requirements set out in BS 6939 Part 1, and FIBCs which are not intended for hazardous materials must not be used for

that purpose.

Some chemicals and minerals are of a specific gravity. As a result, the SWL may be reached w he n t he F I B C i s o nl y pa r t i a l l y f i l l e d. C ar g o we i ght m us t be cl os e l y m o ni t or e d a nd a l l o w ance s made if the contents become wet. During the use and transportation of FIBCs, personnel must:

Page 208 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

1.

Ensure they are filled in accordance

2.

Avoid using sharp hooks or forklift

with manufacturer's

3.

Avoid dragging

4.

Ensure that they do not project over the side of a vehicle

5.

Not stand under a suspended

recommendations.

truck forks, which may damage the lifting

loops.

them along the ground or deck. or trolley.

FIBC.

W he n F I B C s ar e us e d ou t do o r s : 1.

Particular

2.

They must be protected

attention

must be paid to the top closure from rain accumulation,

and its tying off arrangement.

excessively

high temperatures

and

ultraviolet light. 3.

They must not be left standing

in water for extended

periods of time.

DO

DON'T

Do select the right FIBC for the job in consultation with the manufacturer or supplier Do read the instruction Do inspect re-usable

Don't choose FIBCs without consulting the manufacturer or supplier

label on the FIBC

Don't exceed the SWL in any circumstances

FIBCs before refilling

Don't fill the FIBCs unevenly

Do check that the discharge spout is closed off before filling

Don't stop or start suddenly during transportation

Do ensure that the filled FIBC is stable

Don't subject FIBCs to snatch lift and/or jerk stops

Do close the top inlet correctly

Don't drag FIBCs

Do use lifting gear of sufficient capacity to take FIBCs the suspended load

Don't allow personnel under suspended FIBC’s

Do adjust the distance between fork lift arms to the correct width for the FIBC being handled

Don't allow FIBCs to project over the side of v e hi cl e o r pal l e t

Do tilt the mast of t he fork lift truck rearwards to an appropriate angle

Don't tilt the mast of

Do ensure that crane hooks, bars or forklift arms used for lifting are of adequate size and are rounded to at least the thickness of t sling, belt or rope suspension, with a minimum radius of 5 mm.

Don't withdraw the fork lift tines prior to relieving all the load on the lifting dev

the possibility

of static

the forklift forward

Don't stack FIBCs unless sure of stability electricity

Don't use FIBCs in new c onditions withou consulting the manufacturer or supplier

Do protect the FIBCs from rain and/or prolonged sunlight

Don't reuse single-trip FIBCs

Do ensure the FIBCs are adequately secured in transportation

Don't repair heavy duty reusable FIBCs unless the new requirements can be met

50.5

ices

he

Do take appropriate measures in regard to dust control Do c onsider

a

t

Lifting FIBCs

W he n l i f t i ng F I B C s wi t h a f o r k l i f t t r u ck , be s ur e t ha t t he f o r k l i f t t i ne s ar e s pace d co r r e ctl y . A l l lifting loops, sleeves, or other lifting devices are vertical, s

Page 209 of 247

o that no lateral forces will be

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

created in the FIBC. Be sure that the l

SMEP.EP200802258279

MANUAL

REV.1.0

ifting loops are not twisted. Forklift tines

must have

rounded edges and/or protective covers FIBC’s.

50.6

Lifting with Cranes

The hooks, spreader bars or other devices used for lifting, must have rounded edges and/or protective covers.

Safety hooks with an integrated latch to prevent the hook from accidentally sli loops. Hooks must have a sufficiently large radius to prevent squeezing the loop.

pping off the

W he n t he F IB C i s s us pe nde d, t he l o o ps m us t be v e r t i ca l , w i t ho ut a ny t w i s t s o r k no t s .

Fig 75

Lifting of FIBC’s offshore is not allowed. FIBC’s being transported offshore must be transported using a fully certified lifting frame. T

he

lifting frame must be approved by SMEP’s Lifting Technical Authority prior to its utilisation.

50.7

Carrying With Fork Lift Trucks

The forklift truck must be suitable for the load t hanging from the forklift tines, there is a be held close to the mast and as sure that the wheels of the

o be carried. When travelling with a FIBC danger of the truck becoming unstable. The FIBC must

low as possible with the mast

tilted slightly backwards. Make

truck will not damage the FIBC body. The load must not restrict

v i e w o f t he dr i v e r .

Fig 76

FIBCs must not be dragged. The truck must be brought to a stop before the lowered smoothly.

Page 210 of 247

FIBC is raised or

the

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

Fig 77

Page 211 of 247

SMEP.EP200802258279

REV.1.0

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

51.0 Containers The containers referred to here meet BS EN 12079 specifications for freight containers of

the

totally enclosed general purpose type for transportation by road or sea.

Before loading a freight container with cargo, an internal and external inspection must be carried out to ensure that: 1.

The container

shows the tare weight,

payload (SWL), maximum gross weight,

ID

number and date of inspection and next due date. 2.

The attached

lifting

set is within the specified

inspection

period and colour coded

to this effect. 3.

The attached

lifting

angle of 45° to the 4.

set is of the correct length to achieve

the maximum lifting

vertical

Ensure that the attached

lifting

set is of adequate

length to allow the

rigger/slinger to place the master link onto the crane pennant hook without the need to climb. 5.

Shackles

must be of the 4-part bow safety-anchor

type, with retaining

nut and split

pin. Screw pin shackles must not be used. a.

There is no obvious damage such as distortion

of floor/sides/roof,

bent

lifting eyes or cracked welds.

51.1

Wire rope slings

Most containers are fitted with multi-leg wire rope slings, which are rated for use up t angle of 45° (angle measured from the vertical of the diagonally opposite

o an legs) and have an

in-built factor of safety (FOS) of 5: 1. This is based on the maximum gross weight of the container. It is a requirement that any sling set fitted to a container used for offshore lifting an additional safety factor is required to be included. Refer to table below:

Sling Capacity

Safety Factor

Less than 6 tonnes

10

6 to 10

8.5

10 to 15

7.25

15 to 20

6.5

20 to 25

6.25

A l l sl i ngs l e g s , w hi ch a r e c o nne c t e d di r e ct l y t o m a s t e r l i nk s o r s hack l e s , m us t ha v e t hi m bl e s o r hard eyes to reduce the bend radius on the wire rope and therefore increase their serviceable life.

Container sling sets may be fitted with

a top lifting leg or fifth l

eg and master link (fig 78),

w hi ch i s de s i gne d t o ha ng o v e r t he s i de o f t he co nt a i ne r t o f a ci l i t at e ho o k i ng u p. T hi s eliminates the need for personnel having to climb on

top of containers to attach or detach the

Page 212 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

crane hook, which, could be particularly hazardous on marine vessels. This fifth leg is not a design requirement but a more practical method.

Fig 78 Typical

51.2

rigging arrangem

ent for containers

ISO Containers

Even onshore or in still water port situations, ISO containers cannot be corner fittings by shackles and slings or hooks as they

lifted from the ISO

are designed only for vertical lifting.

This applies even when empty. Lifting with spreader frames as used in port situations is

not allowed in offshore lifting

operations. Refer to IMO MSC circular 860. ISO containers used offshore must have pad eyes that are purpose built for offshore lifting. It is appreciated that from time to time there may be

a requirement to send ISO containers or

ISO tanks offshore, which do not comply with Shell Malaysia E situation a fully certified

& P’s requirements. In this

proprietary ISO container-lifting frame must be used. The

ISO container-lifting frame must be approved by SMEP’s Lifting Technical Authority prior to its utilisation.

Page 213 of 247

proprietary

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

52.0 Pennants/Stingers A pe nna nt m u s t be u s e d f o r al l l i ft s t o a nd f r o m s u ppl y v e s s e l s , w or k bo at s e t c. A l l pe nna nt s must be fitted with a scissor action s

elf-latching type hook with trigger release handle; this

ensures that the rigger’s hands are kept away from the hook’s facility to attach the tag line to

52.1

pinch points. It also has the

the hole in the bottom of t

he trigger assembly.

Pennant Assembly

The pennant must be

manufactured in accordance with BS EN 13414-1, from wire

rope, which

meets the requirements of BS EN 12385-4, or an equivalent International Standard. Pennants are required to meet the requirements above and in addition the following requirements: 1.

The construction

shall be with hard eyes terminations,

a hook on one end and a master

link at the other end. 2.

The attached

hook shall be of a swivel scissor

action self-latching

type hook with

trigger release handle design. (See fig 16A). 3.

The hook shall have a working load limit at least equal to the one leg sling working load limit listed in BS EN 13414-1 table 4.

4.

The master link shall be of a suitable

size to fit the crane hook, but must have a

wo r k i ng l o ad l i m i t a t l e as t e qua l t o t he one l e g s l i ng w o r k i ng l o ad l i m i t l i s t e d i n B S E N 13414-1 table 4. 5.

A hi-visibility

6.

Pennants

cover for the wire rope portion is recommended.

shall have a minimum capacity

to lift 125% of the planed load, and the wire

rope shall not have a diameter less that 22mm. 7.

A pennant

must be used for all lifts to and from supply vessels,

work boats etc. In

exceptional circumstances were due to jib length/height restriction it is not possible to use a pennant, a tag line must be attached just

above the crane hook. The crane

operator and vessel's crew must exercise utmost caution.

Fig 79 Typical Pennant assembly

Page 214 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 1

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Crane Banksman Hand Signals

Prior to any lifting operation being made, a banksman is to be appointed and identified to the crane operator. This applies without exception in all cases. The banksman is the only person permitted to pass inst ructions to the crane operator, and the crane operator is not permitted to follow instructions from persons other than the banksman. The banksman must direct lifting operations and signal to the crane operator using standard hand signals as illustrated in Fig 1.

STOP - Extend one arm and hold palm of hand vertical. Note: EMERGENCY STOP is indicated by holding both arms up

STOP (B) - Arm extended, palm down, move hand right and left. Usually for different l operations.

STOP AND LOCK (HOLD EVERYTHING) Clasp hands in front of body.

MOVE SLOWLY - Place one arm motionless across chest in conjunction with or before giving any other directional signal. (“Hoist slowly” shown as example.)

HOIST - With forearm vertical, forefinger pointing up, move hand in horizontal circles.

LOWER - With arm extended downward, forefinger pointing down, move arm in

Page 215 of 247

evel

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

horizontal circles.

USE MAIN HOIST - Tap fist on head, then use regular signals.

USE FLYLINE (AUXILIARY HOIST) - Tap elbow w i t h o ne ha nd, t he n us e r e g ul a r s i gna l s .

RAISE BOOM (LUFF UP) - Arm extended, fingers closed, thumb pointing upward.

LOWER BOOM (LUFF DOWN) - Arm extended, fingers closed, thumb pointing downward.

SLEW - Arm extended, point with finger in direction of swing of boom. OVERHEAD GANTRY CRANE - Arm extended, point with finger in the long-travel or cross-travel direction.

EXTEND HYDRAULIC BOOM OR TROLLEY OUT (TOWER CRANE) - Both fists in front of body w i t h t hum bs po i nt i ng o ut w ar d.

Page 216 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

RAISE THE BOOM AND LOWER THE LOAD (B) - One arm extended, fingers closed, and thumb pointing upward. Other arm extended downward with forefinger pointing down, move arm in horizontal circles.

RAISE THE BOOM AND LOWER THE LOAD (A) - One arm extended, thumb pointing upward flex fingers in and out as long as load movement is desired.

LOWER THE BOOM AND RAISE THE LOAD (A) - One arm extended, thumb pointing downward flex fingers in and out as long as load movement is desired.

LOWER THE BOOM AND RAISE THE LOAD (B) - One arm extended, fingers closed, and thumb pointing downward. Other arm vertical w i t h f o r e f i ng e r po i nt i ng up, m o v e a r m i n horizontal circles.

RETRACT HYDRAULIC BOOM OR TROLLEY IN (TOWER CRANE) - Both fists in front of body w i t h t hum bs po i nt i ng t o w ar d e a ch o t he r .

TRAVEL - Arms bent at the elbows, fist clenched, rotate both forearms around each other, then point in the direction of travel.

Page 217 of 247

s

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

FINISHED WITH CRANE - Place arms head and cross hands.

TRAVEL (ONE TRACK - CRAWLER CRANES ONLY) - Lock the track on the side indicated by the closed fist. Travel opposite track in the direction indicated by circular motion of other fist rotated vertically in front of body.

A c r a ne m u s t no t be o per a t e d un l e s s : 

The banksman has a clear view of the load, lifti

ng assembly and crane operator to give

signals. 

The banksman has checked that riggers and all other personnel are clear of the vicinity of the load.



The crane operator has a clear view of the banksman to receive signals.

Banksmen, riggers and other personnel involved in crane operations must wear safety helmets and other relevant per sonal protective equipment. requirement while he is in the crane cab, operating the crane. Crane activities must cease in the event of any e

The crane operator

is exempt from this

mergency or potentially dangerous situation

and the crane operator must immediately obey all emergency stop signals.

Page 218 of 247

above

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 2

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Flow Chart Lifting and Hoisting Operations LIFT REQUIRED

NON-ROUTINE

Simple Lift

Risk Assessment (New or modified)

Complicated Lift

Lift Plan (New) Approved by TA

APPOINT PIC & DEFINE LIFT

ROUTINE

No

Complex Lift

Lift Plan (New) Approved by TA

Review previous risk assessment and lift plan

Risk Assessment (Generic) Approved by PIC

Proceed and verify lift by toolbox meeting, PTW Page 219 of 247

NEW LIFT

Yes

Changes in situation

Risk Assessment (New or modified) Approved by PIC

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 3

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Mobile Crane Lift Planning Sheet

Description of lift: Location Generic Lift plan No.

Permit to work Number Risk assessment No. 1. CRANE DATA Crane Reg. No. Inspection Date Next due date Crane capacityradius Kgs Max working Mtrs Max boom length Mtrs Max lifting height Mtrs Parts of line The crane capacity charts must be consulted for operation restrictions i.e. over the rear only, outriggers fully extended 2. LOAD DATA Object to be lifted Weight of Load Container/Vessel - Empty YES NO Awkward Shape YES NO CofG Known, could it change YES NO Certified lifting points YES NO Special Rigging required YES NO Special rigging techniques YES NO required Other

3. RIGGING REQUIRED

Shackle Type Shackle set set 1 2 Type Sling set 1 Type Sling set 2 Type 4. RIGGING WEIGHT Description Headache Ball & hook Load line Fly Jib Fly Headache Ball & hook Rigging i.e. sling shackles Spreader bar Other rigging attached Total

Capacity Capacity Capacity Capacity Weight

kgs kgs kgs kgs Units kgs kgs kgs kgs kgs kgs kgs kgs

Quantity Weight Quantity Weight Quantity Weight Quantity Weight 5. RIGGING CALCULATION Description Weight Object weight (2) Contingency % Rigging weight (4) Total weight Maximum Radius Lift height Boom length Capacity chart rating at radius & boom length % of chart capacity % safety margin

kgs kgs kgs kgs Units kgs kgs kgs kgs M M M kgs

6. CATEGORY OF LIFT Tick which ever is applicable Routine  Lift plans shall be written by rigging foreman or crane operator and approved by person in charge (PIC) of the lifting operation.  Simple Lift plans shall be written by a rigging supervisor and approved by person in charge (PIC) of the lifting operation. Complicated  Complicated lift plans shall be written by an approved lift planner and approved by T.A.  Complex Complex lift plans shall be written by an professional engineer and approved by T.A. 7. HAZARDS CRANE SET-UP/OPERATING AREA 7.1 Underground Hazards 7.2 Ground level Hazards 7.3 Above ground Hazards

Page 221 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Utilities – Gas, Water etc Storm Drain Sewer Recent excavations Other - describe

   

AND HOISTING

SMEP.EP200802258279

MANUAL

Members of the public Workers Vehicles/machinery Buildings Ground conditions Other - describe

REV.1.0

    

Electrical cables Telephone cables Lampposts Other cranes Trees Conflicting tasks in area Other - describe

     

Access road: Concrete/Bitumen/Gravel/soft/Other Crane Set-Up Area: Concrete/Bitumen/Gravel/Soft/Slope /Other The lifting activity requires the following to be considered, note this list is not exhaustive Cultural, communication and language difficulties Weight, size, shape and centre of gravity of load Availability of approved lifting points on load Method of slinging/attaching/detaching the load Overturning/load integrity/need for tag lines Initial and final load positions and how it will get there Lifting over live equipment Number and duration of lift(s) 8. PERSONNEL Personnel Crane Operator Banksman Rigger 9. APPROVALS Required lift Approvals Lift plan prepared by Lift plan reviewed by Lift Plan approved by

Environmental weather and permissible limits Illumination in conditions the pick-upincluding and lay-down areas Proximity of hazards, obstructions in the path of load Contingency plan in case the task changes Access and emergency escape routes Experience, competence and training of personnel Number of personnel required for task Pre-Use Inspection of equipment by Operator Tool Box Talk, including Safety and Stopping the job

Name

Signature

Date

Name

Signature

Date

Lifting details (step by step)

Page 222 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 4

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Appliance Lift Planning Sheet

Description of lift: Location Generic Lift plan No.

Permit to work Number Risk assessment No. 1. APPLIANCE DATA Appliance. No. Inspection Date Next due date Appliance capacity Working Height 2. LOAD DATA Object to be lifted Weight of Load Awkward Shape CofG Known, could it change Certified lifting points Special Rigging required Special rigging techniques required Other 3. RIGGING WEIGHT Slings Shackles Other rigging

Kgs Mtrs

YES YES YES YES YES

NO NO NO NO NO

4. RIGGING CALCULATION Description Weight

Units

Object weight (2) Contingency % Rigging weight (3) Total weight Lift height % of capacity % safety margin 5. RIGGING REQUIRED Shackle set 1 Type Capacity kgs Quantity Weight Shackle set 2 Type Capacity kgs Quantity Weight Sling set 1 Type Capacity kgs Quantity Weight Sling set 2 Type Capacity kgs Quantity Weight 6. PRE USE CHECK LIST Item Pre Inspection 1 Examine top and bottom hooks and check for stretch and/or distortion. 2 Check function of safety catches. 3 Ensure hooks swivel freely in yokes and are secure in their mountings 4 Where accessible, examine load pin for wear and/or distortion. 5 Examine load chain sheaves, check for wear and/or distortion and ensure satisfactory seating of load

6 7 8 9

chain. Examine body casing and check for cracks, distortion, missing bolts/screws or any defect, which may affect safe operation. Examine (as far as possible) internal frame side plates. Ensure chain guide rollers and chain stripper are in position and functioning. Examine live end and dead end load chain anchor pins and check for distortion/wear.

Page 223 of 247

kgs kgs kgs kgs M

kgs kgs kgs kgs Yes

No

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

10

Suspend hoist and spin hand chain wheel (in hoist mode) to check ratchet pawl function-listen for healthy clicking sound. 11 Examine hand chain wheel and chain and ensure it seats correctly in the pockets. 12 Examine complete length of load chain and check for stretch, deformed/bent links, nicks, wear and excessive corrosion. 7. CATEGORY OF LIFT Tick which ever is applicable Routine  Lift plans shall be written by a rigging supervisor and approved by person in charge (PIC) of the lifting operation. Non-Routine  Lift plans shall be written by an approved lift planner and approved by T.A 8. HAZARDS APPLIANCE RIG-UP AREA 8.1 Ground level Hazards Workers Obstructions Buildings Other - describe

  

8.2 Above ground Hazards Cables Live lines Conflicting tasks in area Other - describe

  

Appliance Rig-Up Padeye, Trolley, Beam clamp The lifting activity requires the following to be considered, note this list is not exhaustive Cultural, communication and language difficulties Environmental conditions including weather and permissible limits Weight, size, shape and centre of gravity of load Illumination in the pick-up and lay-down areas Availability of approved lifting points on load Proximity of hazards, obstructions in the path of load Method of slinging/attaching/detaching the load Contingency plan in case the task changes load integrity/need for tag lines Access and emergency escape routes Initial and final load positions and how it will get there Experience, competence and training of personnel Lifting over live equipment Number of personnel required for task Number and duration of lift(s) Pre-Use Inspection of equipment by Operator Tool Box Talk, including Safety and Stopping the job 9. PERSONNEL Personnel Crane Operator Banksman Rigger 10. APPROVALS Required lift Approvals Lift plan prepared by Lift plan reviewed by Lift Plan approved by

Name

Signature

Date

Name

Signature

Date

Lifting details (step by step)

Page 224 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 5 Date/Time

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Carrier Transfer Checklist

Reason for Transfer

No of people to transfer

Transfer from:

No

Description

Minimum Requirement

1a

Crane suitability Crane &

The crane is registered and approved for personnel basket transfer with SMEP’s Lifting Technical Authority? Pre-use inspections have been undertaken?

1b

2

3a 3b 3c 3d 4a 4b 5a 5b 6

7 8a

8b

Lifting Equipment Take-off and landing area

Weather criteria Weather criteria Vessel Movement Vessel Movement Communicati on Visibility Transfer carrier Transfer carrier Crane Operator Assisting Personnel Personnel transferring

9

Personnel transferring Personnel transferring Personnel transferring Personnel transferring Briefing

10

Toolbox talk

8c 8d 8e

11

Toolbox talk

12

Recovery Craft

Transfer to:

Crane Driver

SMEP Site Rep

Vessel Master

Are take-off and landing area level, free of obstruction, have a non-slip surface and have sufficient clear space (6m x 6m minimum) for landing the carrier in the prevailing weather condition? Significant wave height not more than 2 m. Mean wind velocity of 10 m/s knots or 6 m/s in weather side. Less than 3 degrees roll. Vessel can hold station for 3 minutes in the required transfer position - verified by Master of vessel Full radio contact between Installation Supervisor, Vessel Master, Crane Operator and Banksmen? Does crane operator have full view of the take-off and landing area including lifting trajectory? Is transfer carrier certified for man riding and in good condition? Two taglines attached to the carrier, and without knots Is crane operator certified by a SMEP approved training provider and assessed for competency and has the experience in carrying out personnel carrier transfers? Banksman with banksman’s jacket and two assistants at the take-off and landing area? All personnel transferring are wearing Coverall, Safety Footwear, Safety Helmet with chinstrap Safety Glasses and an approved buoyancy device? Maximum 3 persons per transfer? Checked for loose items? All passengers agreed to the transfer? An experienced person accompanies inexperienced people. All personnel transferring have received a full briefing and signed form in appendix 6? Toolbox talk held with all personnel involved in the transfer i.e. Crane Operator, Banksman etc? Toolbox talk held by Vessel Master, with Officer and crew? Fast rescue boat deployed?

All the checks found to be satisfactory:

_________________ Work Site Supervisor

Name:

________________ SMEP Site Representative

Name:

Page 225 of 247

_________________ Vessel Master

Name:

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 6

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Carrier Transfer Passenger Checklist

By signing this document, I confirm that the following statements are true: I have received a briefing about personnel transfer by carrier. I understand the procedures shown. I agree to transfer by this method. I understand that this transfer will take place on a voluntary basis only. I am physically fit to transfer, and do not suffer from vertigo (fear of heights). Date/Time

No

Reason for Transfer

Passenger Name

No of people to transfer

Company

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Page 226 of 247

Transfer from:

Position

Transfer to:

Signature

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Appendix 7 Personnel Transfer Request SMEP PERSONNEL TRANSFER REQUEST TRANSFER NO. __________________ DATE________________

COMPANY _________________________

FROM (UNIT) ________________________ TO (UNIT) _________________________ NUMBER OF PERSONS (MAX 3) TIME TRANSFER REQUIRED _______________________ PERMIT TO WORK NUMBER _______________________ REQUESTED BY _________________________________ POSITION _______________________________________ JUSTIFICATION FOR TRANSFER

APPROVAL SMEP SITE REPRESENTITIVE NAME ___________________________________

SIGNED ____________________________

---------------------------------------------------------------------VESSEL MASTER NAME ___________________________________

Page 227 of 247

SIGNED ____________________________

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 8

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Installation Of Wire Rope Double Saddle Grips

W i r e r o pe gr i ps a r e wi de l y us e d f o r m a k i ng e nd t e r m i na t i o ns . G r i ps a r e a v ai l a bl e i n t w o ba s i c designs U-bolt and fist grip. SMEP do not allow the use of U-grips (Bulldog grips) to be used but allow properly designed rope grips with two saddles i.e. fist grips.

Fist Grip W he n m a k i ng up a s l i ng o r t e r m i na t i o n, a l w ay s e ns u r e t ha t : a. Never use fewer than the number of clips recommended

in Table 1

b.

New clips are used; used clips do not have the full holding

c.

A thimb le is inserted in deforming

d. e.

The clips are fitted in accordance with the manufacturer’s instructions All threads and nut bearing surfaces are greased, unless manufacturer’s state otherwise

f.

Full recommended

g.

A record is kept of measured torque values when terminations during each subsequent periodic check

are first m ade and

h.

Periodic

below:

    

the eye of the sling; this prevents

torque settings

checks of torque settings

are achieved,

ability the r ope fr om w earing and

instructions

e.g. 49Nm for 16mm diameter

are carried out as specified

rope

as soon as the service load is hung on the rope after 24 hours in service after 7 days in service after 1 month in service at 6 monthly intervals from the date of installation Stage 1 Turn back specified amount of rope from thimble or loop. Apply first grip one base length from dead end of rope. Tighten nutsfrom evenly, alternating one nut to the other until reaching the recommended torque.

Page 228 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Stage 2 A ppl y t he s e co nd g r i p a s near the thimble as possible. Turn nuts firmly but do not tighten. Stage 3 A ppl y t he r e m a i ni ng r o pe grips equally between the first two Stage 4 A ppl y t e ns i o n i n di r e ct i o n of the arrow, and tighten all nuts to the recommended torque. Remember to check the nut torque after the rope has been in operation. To determine the correctly number of grips to be used for specific diameters of rope refer to table 1 Rope Diameter (mm) 5

Minimum Number of Clips

Rope Turn Back From Thimble (mm)

Torque Un-lubricated Bolts (ft-lb)

2

100

30

6

2

100

30

8

2

130

30

10

2

133

45

12

2

165

65

13

3

280

65

14

3

350

130

14

3

400

130

20

3

450

225

22

4

660

225

25

5

940

225

28

5

1000

360

30

6

1400

360

35

6

1600

500

40

6

2000

500

Table 1 Installation of Double Saddle rope grips (Fist

Page 229 of 247

Grips)

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 9

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Shackle – Split Pin Sizes

Safety shackles are widely used for terminating sling set on to

containers. Safety shackles are

available in two basic designs Bow (anchor) and Dee (chain). It is important that the correct diameter and length of split

pin is used, the table below details

the recommended size of split pin.

SHACKLE WLL

SPLIT PIN SIZE

0.5 te

2 x 20 mm

1 te

3 x 20 mm

1.5 te

3 x 20 mm

2 te

3 x 25 mm

3.25 te

5 x 30 mm

4.75 te

5 x 30 / 35 mm

6.5 te

6 x 35 / 40 mm

8.5 te

6 x 45 / 50 mm

9.5 te

6 x 45 / 50 mm

12 te

6 x 50 / 55 mm

13.5 te

8 x 55 / 60 mm

17 te

8 x 55 / 60 mm

25 te

10 x 70 mm

35 te

10 x 80 mm

55 te

10 x 100 mm

85 te

10 x 110 mm

120 te

13 x 110 mm

Page 230 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 10

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Overload Protection and Anti-Two-Block Requirements

The table shows the overload protection, anti-two-block cut-out, radius or angle indicator boom length requirements for lifting equipment. Equipment

Type

Mobile Cranes – Capacity less than 3 tonne Mobile Cranes – Capacity more than 3 tonne Offshore pedestal Cranes Fixed boom length Fixed Capacity Offshore pedestal Cranes Fixed boom length Variable Capacity Offshore pedestal Cranes telescopic boom Fixed Capacity Offshore pedestal Cranes telescopic boom V a r i abl e Capacity Offshore Swing J i b C r a ne s Fixed boom length – Any Capacity Overhead Travelling crane A ny c apa ci t y (1) Lorry loading crane - Any capacity (2) Forklift trucks A ny c apa ci t y

Radius or angle indicator

Boom length indicator

A nt i twoblock cut-out

Rated Capacity Indicator (RCI) or A SL I

M

M

M

M

M

M

M

M

M

R

M

M

M

and

Load moment limiter or cut-out

Overhoist limiter

R

M

M

M

R

M

M

M

M

M

M

M

M

M

M

M

M(3)

M R

R

Key 1. 2. 3. M R

Not app licable on manually oper ated overh ead cran es For telescopic or straight boom cranes only. This does not (knuckle) boom cranes. Only where the c rane has a hoist winch Mandatory Recommended

Page 231 of 247

Lower hoist limiter

apply to artic

ulating

R

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Appendix 11

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Glossary of Terms

Al pha/numeric

An emometer

A co m bi nat i on o f l e t t e r s a nd/ o r num be r s u s e d f o r identification. Instrument

(used on some cranes) for measuring

wind speed.

Angle Factor

The factor by which the WLL of a multi-legged slings is derated to give its SWL at a particular angle between the sling legs.

A n gl e I n d i c a t o r

A dev i ce t ha t s ho w s t he a ngl e a t whi c h t he cr a ne bo o m i s operating and the corresponding rated capacity.

Anti-Two Block

See Upper hoist – limiting device.

Approved

A ppr o v e d by S M E P T e chni c a l A ut ho r i t y

Asset Owner

Entity that owns lifting equipment. Either SMEP or Contractor.

A u t o m a t i c S a f e L o a d I n di c a t o r ( A S L I ) A dev i c e t ha t a ut om at i ca l l y pr o v i de s , w i t h a s pe ci f i e d or Rated Capacity Indicator (RCI) tolerance, warning the load is approaching the rated capacity, another warning when capacity is exceeded. A u x i l i a r y H oi s t

A s e co nd( a r y ) l i f t i ng s y s t e m , u s ua l l y f i t t e d t o c r a ne s , operating from a separate winch drum from the main hoist rope. Usually used on cranes to lift light loads, relative to the crane’s capacity, faster than is possible on the main hoi st system.

Back Hooking

A m e t ho d o f s l i ngi ng us i ng s l i ng s w i t h ho o k s w he r e t he s l i ng is the load the hook is thepassed ring oraround hook above theand load.

secured back onto

Back Splice

A s pl i c e i n t he e nd o f a f i br e r o pe t o pr e v e nt i t f r o m unl a yi ng .

Banksman/Signaller/Flagman

Person positioned so that he has an unrestricted view of the load and is also in view of the crane driver, so that he may give load-manoeuvring instructions to the crane driver via hand signals or hand-held radio.

Barang Box

A bo x ca r r y i ng g e ne r a l go ods . A t er m w i de l y u s e d i n Malaysia.

Barge List Or Heel Or Trim

Cause swing out of the load and can produce side load.

Barge List and Crane List

These are not the same. As the crane rotates on the barge, it’s list (as defined above ) will change. The worst crane list condition occurs when the crane slews over the barge’s corner producing maximum side load

Basket Hitch

A m e t ho d of s e c ur i ng a s l i ng ar o u nd a n o bj e ct by br i ngi ng both eyes back together with an angle factor = 2.

Becket

A n a ncho r a ge po i nt on a s he a v e bl o ck whe n r e e v i ng a t a ck l e to purchase.

Page 232 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Becket Load

Bilingual Text Blind lifts

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

The load in any fall of rope in a multiple fall tackle. It equals the total load being lifted divided by t he number of falls supporting the load. English

and Bahasa Malaysia

Lifting operation whereby the lifting not have a direct view of the load or l

appliance operator anding area

does

NOTE Use of closed circuit television monitoring the work area is not considered to be direct view. Billy Pugh

The trade name of the offshore in common use.

Block

A hook sheave and frame assembly for raising and lowering loads.

Block and Tackle Boom

rope personnel attached

transfer

to a rope used

A s he a v e bl o ck o r bl o c k s us e d w i t h f i br e r o pe A steel lattice, or steel box section structure that is attached from which the load is suspended and which can be raised or lowered, usually a form of lifting mast.

Boom-Type Elevating

A pow e r e d t e l e s co pi c de v i ce , hi ng e d de v i ce o r

Work Platform

articulated device or any combination of these used to support a platform on which personnel, equipment and materials may be elevated to perform work. Also known as “cherry pickers”

Booming/luffing

carrier

The movement of a crane boom from one angle to another the vertical plane.

in

Bow Shackle

A s ha ck l e w i t h bo w e d s i de s.

Bulldog Grip

A w i r e r o pe gr i p co ns i s t i ng o f a U - bol t , t w o nut s a nd a saddle, usually used to clamp two wire ropes or the same parts of a wire rope. Commonly used for making end terminations NOT ALLOWED WITHIN SMEP.

cm

Symbol for centimetre. 10mm equals one centimetre. 100 cm equals 1 metre.

Calibration

The calibration of test equipment must be in accordance with BS EN ISO 7500-1 or an equivalent standard. Accuracy of calibration in all cases must be within ±2% on the nominal load/force.

Cantilever Beam Cargo

Centre of Gravity

Certificate of Inspection or Test Certificate

Section of beam supported Any liquid, solid or gaseous container.

at one end only. matter transported

in an offshore

Point at which the total mass of a body may be regarded as being concentrated, or about which the parts of the body exactly balance each other.

A C e r t i f i cat e o f T e s t i s s ue d by t he t hi r d pa r t y ce r t i f i ca t i o n authority surveyor on completion of a satisfactory survey. A new Test Certificate will require to be issued i f the equipment

Page 233 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

is subject to repair or modification. Where a Test certificate states that it is als o a report of thorough inspection/examination it must contain all of the information as required by LOLER 98, Schedule 1. A do cum e nt i n whi c h t he m a nuf a ct u r e r ce r ti f i e s t ha t t he products supplied comply with the requirements of the purchase order, without mention of any test results.

Certificate of Compliance

Certificate or Declaration of Conformity

A document in which the manufacturer or other responsible person with legal duties of a manufacturer and who controls the technical file , confirming that an item to which it refers complies fully with an applicable standard and that all essential safety requirements have been met in full. It must give the following information:I.

The business

II.

The responsible

name and full address. person

III.

Where that person is not the manufacturer importer, that of the manufacturer.

IV.

A full description of the equipment type and serial number.

V. VI. VII.

including

e.g. a make and

I ndi ca t e al l o f t he r e l ev a nt pr o v i s i o ns w i th w hi ch t he i t e m complies. Spe ci f y t he s t a nda r ds a nd t e chni ca l s t a nda r ds us e d. I de nt i f y t he pe r s o n a ut ho r i s e d t o s i gn t he c e r t i f i ca t e on behalf on the responsible person.

Chain Block

A ge a r e d po r t a bl e appl i a nce us e d f o r ho i s t i ng and l o w e r i ng a load suspended on a chain.

Cherry Picker

See Boom-type elevating work platform.

Choke Hitch

A m e t ho d of s e c ur i ng a l o a d t o a s l i ng o r a s l i ng t o a n anchorage by reeving the sling back through its eye, or fixing the eye back to the sling leg with a shackle.

Classification Society Surveyor

A person from a classification society who has the appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly inspected as will enable them to detect defects or weaknesses and to assess their importance in relation to the s afety and continued use of the lifting equipment.

Circumference

The distance around the outside edge of a circle.

Clevis

A n e y e w i t h a r e m o v a bl e pi n.

Colour Code

Come-Along

A method of marking equipment (normally with plastic tiew r aps o r pa i nt ) t o g i v e a v i s ua l i ndi c a t i o n o f i t s certification/inspection status. This 'coded' c olour is ch anged every six months. See Ratchet lever block

Page 234 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

Container

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Any form of unit or device used for the transportation cargo.

of

Crane

A n a ppl i a nc e i nt e nde d f o r r ai s i ng a nd l o w e r i ng a l o ad a nd moving it horizontally, but excluding industrial lift trucks earthmoving machinery and lifts.

Crane Chart

See Load chart or

Crane Operator or Driver

The person who is operating the crane for the positioning loads.

Crane, Crawler-M ounted

Except for the base these cranes are identical to Mounted

Crane List

Cross Hauling

Documented Training

Capacity chart. purpose of

the Carrier-

As the crane’s out-of-level condition, from side to side, as measured by the angle between horizontal and a line drawn through the centreline of the crane’s boom heel pins. This outof-level condition creates side load and effects the crane’s lifting capacity. Process of moving a load in a direction other than vertical, for purposes of access/egress (sometimes called Fleeting). This action is usually carried out using chain blocks and pull lifts and the equipment used is down-rated. Training whereby it can be documented that the person who w i l l us e t he l i f t i ng e qui pm e nt ha s r e c e i v e d pr a ct i cal and theoretical training that provides knowledge about its structure, operation, applications, limitations and scope of use, as well as maintenance and inspection in accordance w i t h t he r e qui r e m e nt s s e t f o r s af e u s e a nd o pe r a t i o n stipulated in regulations and instructions for use

Drawn-up Dimension

The minimum distance between the suspension level and the bottom hook saddle (also known as closed-height).

Dead end

The tail of a rope which does

Dee Shackle

A s ha c k l e wi t h par a l l el s i de s , r e s e m bl i ng t he l e t t e r D o n i t s sides.

Diameter

The distance across a circle measured through its centre.

Diverting Sheave

A s he a v e se t up t o cha ng e t he di r e ct i on o f t he l e a d r o pe between the winch and the head sheave.

Double Wrap

A m e t ho d o f s l i ng i ng w he r e t he s l i ng l e gs ar e pa s s e d t w i ce round the load with the eye chocked back to the sli ng.

Dunage

Packing under loads.

Effective Span

The distance between the centres of the adjacent due allowance the end fixing, continuous beams cantilevers.

Effective Working Length (EWL)

The distance between the extreme inside ends straight sling.

Effort

The pull on the hand chain or lever required to lift a specified load (chain blocks and pull lifts). The s pecified load is usually the working load limit of the block.

Page 235 of 247

not take load.

supports, and

of the eyes in a

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Elevating Work Platform

A t e l e s c o pi c de v i ce s ci s s or de v i ce o r ar t i cu l at i ng de v i ce us e d to support a working platform.

Elevator

A l i f t i ng de v i c e , w i t h hi nge d do o r s a nd a f a s t -r el e a s i ng l at ch, w hi c h ha ng s o n l o ng l i nk s be l o w t he t r av e l l i ng bl o ck and hook, and which, in a closed position fits snugly around the drill pipe or casing, to handle lifting or lowering of a string.

Elevator Link

A l o ng s t e e l l i nk , w hi c h co nne ct s t he e l e v at o r s t o t he m a i n hook.

Equalising Beam

A l i f t i ng be am , whi c h c an be us e d w i t h t w o cr a ne s t o e ns ur e that each crane is supporting its correct portion of the load.

Equalising Sheaves

Sheaves used to equalise the load.

Eyebolt

A l i f t i ng r i ng fi x e d t o a t hr e a d r od, w hi ch ca n be s cr e w e d i nt o a load or anchorage.

Examination

A v i s u al e x a m i na t i o n by a n i nde pe nde nt t hi r d pa r t y s ur v ey o r carried out carefully and critically and supplemented by other means, such as measurement and where necessary nondestructive testing, in order to arrive at a reliable conclusion as to the condition and safety of the lifting equipment. If necessary for the purpose, parts of the lifting equipment shall be dismantled.

Extended Dimension

The distance between the suspension level and the bottom hook saddle of a chain block, when the bottom hook is in the extended position. It equals the sum of t he drawn up dimension and the range of lift (or height of lift).

FIBC

Flexible Intermediate Baulk Container, commonly known as big bags.

FMEA

Failure Mode Effect Analysis.

Factor of Safety

The ratio of the load that would cause failure of an item of lifting equipment to the load that is imposed upon it in service i.e. SWL (This is t o allow for detrimental criteria such as wear and tear, dynamic loadings etc).

Falls

The passes of a rope in a

Ferrule/Swag

ed fitting

Fit-for-purpose

winching/pulley system.

A metallic fitting, which wire rope can be inserted permanently attached using radial pressure (swaging) the sleeve that enclosed the rope to form an eye.

and then

Equipment free from defect and used only in the manner for w hi c h i t w a s de s i gne d.

Fist Grip

A w i r e r o pe gr i p co ns i s t i ng o f a t w o s a ddl e s a nd t w o nu t s , usually used to clamp two wire ropes or the same parts of a w i r e r o pe . C om m o nl y us e d f o r m a k i ng e nd t e r m i na t i o ns .

Fixed Lifting Equipment

Lifting equipment permanently installed on a Platform normally located at the same point on the Platform throughout the life cycle of the Platform (e.g. pedestal cranes, gantry cranes, swing jib cranes, runway beams, beam, padeyes etc).

Page 236 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Fleet Angle

The angle formed from the centre line of the drum to the centre of the first lead sheave then back to the inside centre of the drum flange.

Fleeting

A m e t ho d o f m o v i ng a n o bj e ct by us i ng t w o ho i s t s , t a ck l e s t o lift, haul and lower the load.

Flemish Eye

A m e t ho d of fo r m i ng a n e y e i n F SW R by s e pa r a t i ng a nd r e marrying the strands without tucks.

Fly Jib

A s e co nda r y j i b m ou nt e d at t he he a d o f t he cr a ne ’ s m a i n boom or jib, increasing the crane operating radius. Also know as “goose neck”

Forerunner

See Pennant

Frame

The primary load bearing elements of a container.

Free Fall

A bo o m o r ho ok - bl o ck de s ce ndi ng unde r i t s ow n w e i g ht , o r that of the load.

Free on Wheels

A bl e t o l i f t l oa d w i t h a w he e l e d cr ane w i t ho ut u t i l i z i ng t he outriggers or stabilisers.

Frog

The trade name of the buoyant enclosed personnel transfer capsule marketed by Reflex marine. Which, is a conical shaped solid cage with three seats, designed for the aerial transport of personnel by an offshore crane .

Functional Testing

Operation of each motion of the lifting equipment without a load applied in order to determine whether the equipment performs as the manufacturer intended.

FSWR

Flexible Steel Wire rope

Gantry

Elevated structure supporting the track of an overhead travelling trolley or crane.

Gin Wheel

A pur po s e -des i g ne d s i ngl e -s he a v e t a ck l e bl o ck .

Girder/Beam Clamp

A n a ppl i a nc e de s i gne d t o be f i x e d t o t he l o w e r fl a ng e o f a universal beam or RSJ to provide and anchorage for a sing, suspension rope or tackle.

Goose Neck

See Fly Jib.

Grommet

A n e ndl e s s s l i ng co ns t r uc t e d w i t h a s l i ng r o pe s t r a nd l a y e d up onto itself.

Gross Weight (containers)

The maximum allowable weight of a loaded container, at the design sling angle, i.e. the Tare w eight (weight of empty container) plus the Pay Load (maximum weight of cargo, that can be carried by the container).

HAZID

Hazard Identification

HAZOP

Hazard and Operability Analysis

HEMP

Hazard and Effects Management Process. T he structured hazard analysis methodology involving hazard identification, assessment, control and recovery, and comparison with

Page 237 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

screening and performance criteria. To manage a completely requires that all four steps must be in place and recorded. HIP

hazard

Hazard Identification Plan – A document that identifies possible hazards and the actions necessary to minimise risk.

Hammer Locks

A n a t t a chm e nt f o r j oi ni ng ho o k s o r r i ng s t o a cha i n.

Hand Operated Chain Hoist or Chain Block

A bl o c k r e ev e d w i t h a l o a d cha i n a nd o pe r a t e d by a ha nd chain so as to give a mechanical advantage (also known as a chain block).

Headache Ball

A s phe r i ca l ov e r ha u l i ng w e i ght a t t a che d t o s i ng l e f a l l ho i s t above the hook block.

Headroom

The maximum vertical distance between the item to be lifted and the point of suspension of the hoisting machine. e.g. between the lifting padeyes and the underside of runway beam.

Height of Lift

The amount of possible travel between the t op and bottom connection points (e.g. hooks) of a hoisting machine.

Hook Block

The lower block on a crane, which incorporates a hook for sling loads.

Hook Load

The total weight suspended form the hook.

Hoisting

Raising or lowering a load

Inertia Forces

The forces produced by a change of velocity.

Inspection

A v i s u al i ns pec t i o n by a a n i nde pe nde nt t hi r d par t y s ur v e y or carried out carefully and critically for anything which may impair the safe operation of the lifting equipment.

Inspector

The term inspector is used to describe any person carrying out NDT inspection on lifting equipment. In all cases, the inspector shall have experience and training suitable to the NDT inspection being performed.

Jack

A n a ppl i a nc e , w hi c h i s pl a ce d unde r a l o a d t o r ai s e o r l o we r it.

Kg

Kilogram

Kinking

Damage to a rope indicated by sharp permanent twist.

Kilogram

A u ni t f o r m e a s ur i ng m a s s ( o r w e i g ht ) O ne l i t r e o f w a t e r w e i ghs o ne k i l o g r a m . he r e a r e 1 0 0 0 k g i n a t o nne .

Kilo Newton

A u ni t f otor amweight e a s ur iofng100kg f o r ce . O ne k i l o N e w t on i s a ppr ox i m a t el y equivalent

Langs Lay

A c o ns t r uct i on m e t ho d f o r F S W R w he r e t he w i r e s i n t he s t r a nd and the rope strands are laid in the same direction.

Page 238 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Lattice Boom Crane

A cr a ne w i t h an o pe n- w e b bo o m , u s u al l y i n s e ct i o ns . Normally of a fixed length and cannot telescope.

Lay

The way a rope is constructed.

Left Hand Lay

A m e t ho d of r o pe co ns t r uc t i o n w he r e t he s t r a nds ar e l a i d up in an anti-clockwise direction. Sometimes called an ‘S twist’ because the strands run the same direction as the central part of the letter S.

Lifting Appliances

Lifting Tackle Inspector

Lifting Tackle or Lifting Accessory or Lifting Gear

Lifting appliances (overhead cranes, winches, but excluding haulage apparatus).

chain hoists,

etc

A pe r s o n f r o m a t hi r d pa r t y ce r t i f i ca t i o n a ut ho r i t y w ho has the appropriate practical and theoretical knowledge and experience of the lifting tackle to be thoroughly inspected w hi c h e na bl e s t he m t o de t e ct de f e ct s o r we a k ne s s e s a nd t o assess their importance in relation to the s afety and continued use of the lifting tackle. A ny i t e m w hat s o ev er , w hi ch i s u s e d o r de s i g ne d t o be us e d directly or indirectly to connect a load to a lifting appliance, a crane or chain block etc, and which does not form part of the load, but which is not itsel f able to lift or lower a load, e.g. slings, shackles, eyebolts, etc.

Lifting Equipment

A g e ne r i c t e r m co v er i ng a l l e qui pm e nt us e d t o l i f t a nd l o we r a load.

Lifting Operation

A t a s k c o nc e r ne d w i t h t he l i f t i ng a nd l o w e r i ng o f a l o a d. I t includes the selection attachment and use of suitable lift ing equipment.

Lifting Point

Generic term for the certified point(s) or attachment(s) on an item of plant, by which it can be l ifted safely. The term also applies to points or attachments fixed to st ructural members and from which a load can be suspended. For example lifting lugs, lifting eyes, trunnions, fabricated lifting plates, padeyes and jacking points.

Lifting Plan

A do cu m e nt pr o duc e d by t he l i f t pl anne r t o de s cr i be ho w t he lifting operation should be carried out, including any contingency plan if the operation becomes interrupted (e.g. because of weather change, break down etc.)

Lift Planner

A pe r s o n w ho has appr o pr i at e pr a ct i ca l and t he or e t i ca l knowledge and experience of the lifting operations to enable them to prepare a full working lift plan.

Lifting Set/Sling Set

Lifting slings and shackles used to connect a lifting equipment.

Lifting Technical Authority

The Lifting Technical Authority is responsible for assuring the technical integrity of an operational facility, in the context this document this covers approval of this document, and

Live Loads

container to the

of

deviations from this document. A ny l o a d, e x ce pt wi nd l oa d, t ha t gi v e s r i s e t o a v a r i a t i o n o f stress in to a cran e. Such variation may be due to any change of position or magnitude of an externally applied load, or to the movement of the crane st ructure itself.

Page 239 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Load Line

A w i r e r o pe s us pe ndi ng a ho o k .

Load Chart

A m a nu f a ct ur e r ’ s no t i ce f i xe d t o a cr a ne o r ho i s t , w hi ch specifies the SWL’s in all normal operating configurations.

Load Factor

The fraction of a sling assembly’s WL L created by a particular sling method. It includes the angle factor and the reeve factor.

Load Weight Indicator

A dev i ce , w hi c h i ndi ca t e s t he we i ght o f t he l o a d be i ng l i f t e d.

Lorry Loading Crane

A pow e purpose r e d s l e of w iloading ng cr aand ne m o unt e d the onlorry. a v e hi cl e f o r t he principal unloading

Luffing

See Booming .

M

The symbol used to indicate the diameter of a structural bolt in millimetres. For example, M16 indicates a 16mm bolt.

m

A m e t r e – t he u ni t f o r m e a s ur i ng di s t anc e - 1 0 0 0 m e qua l o ne kilometre.

mm

Millimetres – the unit for measuring distance - 1000mm equal one metre.

MOU

Mobile Offshore Unit.

Manila

Sisal, A natural fibre used for rope construction.

Marlin Spike

A t a per e d hand t o o l us e d t o pr y o pe n t he s t r a nds o n an F S W R during splicing or during rope inspection.

Marine Vessel

For the purposes of this document, interpreted as meaning:-

marine vessel shall be

Barge (towed) Barge (self propelled) Pontoon Pipe Laying Barges Cargo Barge W o r k B o at Crane Barge Measured Deflections

Mechanical Advantage

The deflections measured in such a manner that they relate t precisely the same conditions as those covering the calculated deflection. The ratio between the load raised and the effort required raise it.

o

to

Mobile Crane

A cr a ne w hi ch c an t r a v e l o v er a s uppor t i ng s ur f a ce w i t ho ut the need for fixed runways or railway tracks and which relies on gravity for stability.

Mode Factor

A f a c t o r , w hi ch t a k e s i nt o a cc ount t he ge o m e t r y o f t he s l i ng assembly, the number of parts and other constants as specified in the appropriate British Standard.

Multi-Legged Sling

A s l i ng a s s e m bl y w i t h m o r e t ha n t w o s l i ng l e g s .

Page 240 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

SMEP.EP200802258279

MANUAL

REV.1.0

Multiple Crane Lift

The movement of a load where the load is or more cranes.

suspended from two

NDT

Non-Destructive Testing.

Net Capacity (Cranes)

The net capacity is determined by deducting the crane capacity deductions from the crane’s gross capacity. The deductions differ from manufacturer to manufacturer as well as between crane types. Deductions normally are: W e i ght o f m a i n ho o k bl o ck W e i ght o f s l i ngs a nd r i ggi ng W e i ght o f a ux i l i a r y hoo k bl o ck W e i ght o f a l l w i r e r ope f r o m bo o m t i p a nd t he bl o ck W e i ght o f a ny s t o w e d j i b

Non-Destructive Examination (NDE)

The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect, locate, measure, and evaluate flaws; to assess integrity, properties, and composition; and to measure geometrical characteristics.

Non-routine Lift

A l i f t i ng t a s k t ha t i s o f gr ea t e r c o m pl e x i t y t ha n a r o ut i ne l i f t , such that it requires specialist resources and guidance and special procedures written to enable its safe completion. These lifts are normally subdivided into simple, complicated and complex lifts.

Offshore Container

Transportable unit for repeated transport of load or equipment, a unit that can be handled in open sea installations and vessels

to/from

NOTE 1 The unit includes equipment for lifting, handling, filling, emptying, cooling and heating etc. NOTE 2 There are two categories of offshore container: 1. Offshore freight container a. Freight container for

dangerous goods.

b. Freight container for non-hazardous load that is not covered by the IMDG code. 2. Offshore service container Service container produced and equipped for special mainly for temporary installation. Offshore Crane

use,

Slewing crane for general use mounted on an installation and w hi c h or i s semi-submersible u s e d t o ha ndlinstallations e l o ads t o a nd f r o m s uppl y bo a t s , barges

Operating Level

The level on which the operator stands.

Page 241 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

On Rubber

The operation of a truck-mounted or rough terrain mobile crane without the aid of outriggers.

Ordinary Lay

See Right Hand Regular lay.

Outrigger

A hy dr a ul i c s ta bi l i s i ng e x t e ns i o n f o r a m o bi l e cr a ne .

Overload Testing (Static)

Operation of the lifting equipment with a load exceeding the rated load but without operating the full range of motions of the equipment in order to determine whether the equipment is stable, structurally sound and fit for the use for which it designed.

was

Overload Testing (Dynamic)

Operation of the lifting equipment, in all pos sible motions w i t h a l o a d t hat e x ce e ds t he r a t ed l o a d a ppl i e d i n o r de r t o determine whether the equipment is stable, structurally sound and fit for the use for which it was designed.

Payload

The maximum permissible weight of cargo which may be safely transported by the container.

Parts of Rope

See ‘falls’

Permanently Attached Slings Sets

Permanently Attached Slings Sets are used only for transportation of containers. They must not be used for general lifting duties. These slings are colour coded Purple w i t h a ba nd o f t he cur r e nt co l o ur co de .

Permissible Working Stress

The stress numerically equal to the basic stress, the relevant duty factor corresponding to the load.

Performance Testing

Operation of each motion of the lifting equipment with the rated load applied in order to determine whether the equipment performs to the manufacturer’s specification.

Person In Charge (PIC)

Person who is approved by SMEP’s Lifting Technical Authority to be in charage of a lifting operation.

Personnel Carrier

Carrier designed for the aerial transport by an offshore crane “FROG” or Esvagt.

multiplied by

of personnel

usually

Billy Pugh -

A pe r s o nne l tr a ns por t de v i ce co m po s e d o f a s o l i d cyl i ndr i c al platform, flexible sidewall rigging, lift cumulator ring and lifting loadline system designed for the aerial t ransport of personnel by an offshore crane. (Not used in SMEP)

Pendant

A r ope u s e d t o pr o v i de s uppo r t t o l e ng t h o f a cr a ne boo m o r jib.

Pennant/Stinger

A single wire rope sling with an eye on one end and a hook on the other usually suspended from the crane’s hook. Sometimes called a extension sling or forerunner.

Pendant Control

A ha nd-he l d s e t o f m o t i o n c o nt r ol s a t t a che d t o a cr a ne o r hoist by an extension cable to provide operation. Particularly used with some types of overhead travelling cranes and powered-operated chain blocks.

Plant

Generic term covering, machines, sub-assemblies and structures.

Page 242 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Plant/Identification Number

A uni que num be r g i v e n t o a n i t e m o f l i f t i ng e qui pm e nt o r registration purposes and to facilitate traceability.

Plate Clamp

A pur po s e des i gne d i t e m o f e qui pm e nt f o r l i f t i ng s t e e l pl a t e and similar items, usually used in pairs.

Portable Lifting Equipment

Lifting equipment, which can be transported from one part of a platform to another or between different platforms. (chain blocks, lever hoists, beam clamps, Tirfors, etc)

Proof Load Test

A t e s t l o a d ( m a s s o r f o r ce ) a ppl i e d t o a n i t e m o f l i f t i ng equipment/accessory to prove its integrity. Proof load tests can be carried out to various standards, but results must be recorded on a Test Certificate.

Pre-Use And Post-Use Check

Visual and functional assessment (not test) of the lifting equipment’s technical condition before and after use (without disassembly)

Pulley (or Sheave)

A g r o o v e d w he e l o v e r w hi c h a r o pe pa s s e s . P u l l e y s a r e usually shaft mounted and free to rotate in response to movement of the rope.

RCI

Rated Capacity Indicator.

Rotation Resistant (RR)

FSWR in which adjacent layers of strands are laid in directions, i.e. alternative right hand and left hand to prevent the rope from spinning under load. Commonly used as a crane hoist rope, sometimes called non-rotating rope.

Radius (Slewing Cranes)

Horizontal distance between the point at which the centre of rotation meets the ground and the vertical centreline passing through the load lifting attachment

Radius (Non-Slewing Cranes)

Horizontal distance from the centreline through the load lifting attachment to the nearest axle or track measured at ground level.

Radius Indicator

A de v i c e t ha t s how s t he r a di us a t w hi c h t he c r a ne bo om i s operating and the corresponding rated capacity.

Range of Lift

The vertical distance that the bottom hook travels between the extended and highest positions.

Ratchet Lever Block

A ge a r e d po r t a bl e a ppl i a nc e i nco r por a t i ng a l o a d c hai n, w hi c h i s o pe r a t e d by a l e v e r ha ndl e .

Rated Capacity Limiter

opposite

A device that automatically provides, with a specified tolerance, motions that could increase risks, if the rated capacity is exceeded.

Rated Capacity Indicator

See ASLI

Responsible Person

Refer to Person in Charge (PIC).

Reeving (crane)

Configuration of the hoisting rope in a winching system.

Reeving (rigging)

A m e t ho d o f s l i ngi ng w he r e t he s l i ng pas s e s bac k t hr o ug h itself reducing the safe working load.

Rigging

The use of mechanical load shifting equipment and associated gear to move, place or secure a load including plant,

Page 243 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

equipment or members of a building or structure and to ensure the stability of those members and for the setting up and dismantling of cranes and hoists, other than the setting up a crane or hoist which only requires the positioning of integral outriggers or stabilisers. Rigging Screw or Turnbuckle

A n e ncl o s e d de v i ce w i t h a n ancho r a ge po i nt a nd t hr e a de d r o d in each end. Used to tension an FSWR or to provide fine adjustment to a sling assembly.

Rigging Store

A n o f f s hor e co nt ai ne r , o r s i m i l a r , m o di f i e d s pe ci f i c al l y t o s ui t the storage of lifting equipment (often equipped with l ighting and heating).

Right Hand Lay

A m e t ho d of r o pe co ns t r uc t i o n w he r e t he s t r a nds ar e l a i d up in a clockwise direction. Sometimes called a ‘Z twist’ because the strands run in the same direction as the central part of the letter Z.

Risk Assessment/JSA

J o b Sa f e t y A nal y s i s ( J S A ) i s t he a ppl i c a t i o n o f t he ha z a r ds and effects management process at the task level, identifying and assessing the hazards of each element of the task and defining appropriate controls and recovery measures. The methodology is derived from the work study technique known as Task Analysis, and is known variously as Job Hazard A na l y si s ( J H A ) , W o r k S a f e t y a nd H ea l t h A nal y s i s , A ct i v i t y Risk Assessment (ARA). Refer E95 – 0311

Rigger/Slinger

The person responsible for attaching and detaching the load to and from the crane and for correct selection and use of lifting tackle.

Rolled Steel Joist (RSJ)

A s t r uct urby al the s t euniversal e l m e mbeams be r wi(UB’s). t h a n I -s e ct i o n, no w l a r ge l y superseded

Rough Terrain Crane

Short wheel based mobile crane designed to operate on unimproved natural terrain and disturbed terrain of construction sites, with crab steering, and fitted with oversized tyres to facilitate travel across rough terrain.

Round Sling

A n e ndl e s s s y nt he t i c f i br e s l i ng c o ns t r u ct e d w i t h a ci r cu l ar cross section.

Routine Lifts

Those lifts undertaken on a day-to-day basis that are fully addressed by existing 'generic' training and competence procedures.

Runway Beam

A n o v e r he a d s t r uc t ur al be am c e r t i f i ed t o a s pe c i f i c S W L a nd used for the attachment of lifting equipment, such as trolleys, beam clamps, etc.

SLI

Safe Load Indicator.

Safe Working Load (SWL)

The maximum load (as certified by an independent competent person), which anparticular item of lifting equipment may raise, lower or suspend under service conditions.

Serving/ Sizing or Whipping

The binding, in wire or twine, at the the strands from opening or fraying.

Page 244 of 247

end of a rope to prevent

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Sling Assembly

A s l i ng i n t he f o r m i n w hi ch i t i s ac t ua l l y u s e d.

Soft Eye

A n uns u ppo r t e d l o o p, i . e . i s no t pr o t e ct ed by a t hi m bl e , a nd formed at the end of a rope to facilitate connection of a lifting device.

Sheave

A gr o o v e d w he e l ov e r w hi c h a r o pe pa s s e s ov e r .

Sheer legs

A de r r i ck l i k e a ppl i a nce co ns i s t i ng of t wo l e gs i n a n ‘ A ’ formation, with sheave block fixed to its apex and i na framework.

Sisal

V e g e t a bl e f i br e o bt ai ne d f r o m t he s i s a l pl ant . So m e t i m e s us e d to construct natural fibre ropes.

Significant Wave Height

Average height of the highest third of prevailing typically measured over a period of three hours.

waves,

NOTE A s a r ul e o f t hu m b, s i g ni f i ca nt wa v e he i ght i s a bo ut ha l f t he maximum wave height. Slewing

The left and right movement of a crane boom pivoting on it base in the horizontal plane.

s

Sling

Detachable lifting gear made from FSWR, chain or synthetic fibre.

Sling Angle

The angle the sling makes with the horizontal. Maximum allowed is 90º included angle or 45º to the vertical.

Snatch Block

A s i ng l e pul l e y s hea v e bl o ck wi t h a dr o p s i de pl at e t o a l l ow easy access to thereeving pulley itwheel for rope attachment or removal without through.

Spreader Bar/Beam

A be a m / bar w i t h a c e nt r al l i f t i ng at t a chm e nt a nd w i t h slinging points at each end. Used to reduce the angle of slings or to sling loads with large surface areas or to reduce the strain on load.

Stinger

See Pennant

Strand

A num be r o f w i r e s or fi br e s l ai d i n a s pi r a l , w hi ch i s l a i d up w i t h o t he r s t r ands t o f o r m a r o pe .

Strop

A n e ndl e s s sl i ng .

Structural Integrity

The reliability of the load

Statement of Conformity

A s t a t e m e nt i s s ue d by t he m a nuf ac t ur e r c onf i r m i ng t hat a ny necessary manufacturing tests have been carried out, and confirming the SWL. The statement has the same status as a test certificate and must be retained for inspection when required.

Surveyor

A pe r s o n f r o m a t hi r d pa r t y ce r t i f i ca t i o n a ut ho r i t y w ho has the appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly inspected as will enable them to detect defects or weaknesses and to assess their importance in relation to the s afety and continued use of the lifting equipment.

Page 245 of 247

bearing structure.

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Swaged Fitting

See Ferrule.

Swivel

A r ot a t i ng i t e m of l i f t i ng g e a r , w hi ch ca n r o t at e w i t ho u t spinning the rope, hook or load.

Synthetic Fibre

Manufactured fibre used in the construction of fibre ropes and slings, such as polyamide (nylon), polyester, polyethylene, polypropylene etc.

T

Symbol indicating Grade 80 chain.

te

Symbol for tonne. (1000kg)

Tank Container

A c o nt ai ner t ha t co ns i s t s o f t he t a nk or t a nk s , a nd t he l o a d bearing structure.

Tagline

A f i br e r o pe at t a che d t o a s u s pe nde d l oa d t o co nt r o l t he l o ad during lifting.

Tare weight

The weight of the container without cargo. Tare weight shall include all fixtures normally fixed to the container in service.

Telescopic

The extension or retraction of a crane’s boom or jib by t movement of the boom or jib sections during normal operation. A feature of most hydraulic boom cranes.

Test Certificates

A T e s t C er t i f i cat e i s t he ce r t i f i ca t e o f a pr o o f l o a d t e s t , w hi ch w oul d no r m a l l y be ca r r i e d ou t a t t he com pl e t i o n o f manufacture and be supplied with the equipment. A new Test Certificate may require to be issued if the equipment is subject to repair or modification, or if the independent competent person deems it is necessary to ensure continuing integrity.

Test Load

he

Specified load that the lifting equipment shall withstand w i t hi n t he m a nuf a ct ur e r ’ s s pe ci f i e d l i m i t s w i t ho ut r e s ul t i ng i n permanent deformation or other defects, and thereby confirming that the design, materials and manufacture comply w i t h s pe c i fi cat i o n a nd s t at ut o r y r e qu i r e m e nt s

Thimble

A gr o o v e d pi e ce o f m e t a l , ci r cu l a r o r pe a r - s ha pe d, u se d t o protect an eye splice. It forms a ‘hard eye’

Thimble Eye

A l oo p f o r m e d a t t he e nd o f a r ope a r o und a s uppo r t i ng m e t a l eye, i.e. the thimble.

Thorough Examination

A v i s u al e x a m i na t i o n and c e r ti f i c at i on o f l i f t i ng e qui pm e nt carried out by a surveyor from an third party certification authority in accordance with IMP 0.03 Lifting Equipment SMEP.EP72.ST.0032 and any subsequent amendments thereto. The inspection carried out by the surveyor shall carefully and critically, supplemented by other means, such as measurement and where necessary non-destructive testing, in order to arrive at a reliable conclusion as to the condition and safety of the equipment. If necessary for the inspection, part of the equipment shall be dismantled. The surveyor shall be independent of the supplier of Lifting Equipment.

Ton (T) or long ton

For the purposes of the lifting equipment management documents, one long ton shall be interpreted as 2240 pounds, w hi ch i s 1 0 1 6 k i l og r a m s .

Page 246 of 247

Shell Exploration & Production, ASIA PACIFIC SMEP LIFTING

AND HOISTING

MANUAL

SMEP.EP200802258279

REV.1.0

Ton (short) or US Ton (T)

For the purposes of the lifting equipment management documents, one short ton shall be interpreted as 2000 pounds, which is 907.18 kilograms.

Tonne / metric ton (te)

For the purposes of the lifting equipment management documents, one tonne shall be interpreted as 1000 kilograms.

Toolbox Talk

A s ho r t di s cu s s i o n he l d be t w e e n al l m e m be r s o f a l i f t i ng operation prior to commencement of work in order to agree on all aspects of the work and the sequential steps to be taken to complete the work. The agreed procedu re, hazards and control methods are to be recorded.

Transit Slings

Transit slings are used only for transportation of equipment to and from offshore platforms. They must n ot be used general lifting duties, however they can be used to return an item of equipment onshore.

Trigonometrica

l Method

for

A m e t ho d t r adi t i o na l l y us ed t o c al cu l a t e t he S W L o f s l i ng s w i t h t he s l i ng l e g s a t v ar i o us a ngl e s .

UB

Universal Beam

Upper Hoist – Limiting Device

A dev i ce us ed i n a cr a ne o r hoi s t t o s t o p t he w i nch o r w a r n the operator before the hook block jams into the head block (two-blocking) while the hook is being raised.

Universal Beam (UB)

A n I s e c t i o n s t e e l be a m com m o nl y us e d i n s t e e l s t r uct ur e s .

Uniform Load Method

A m e t ho d o f r a t i ng m ul t i -l e gg e d s l i ng s f o r us e a t a ny i nc l ude d angle between the sling legs of up to 90° and 120°. This is the preferred method for rating general-purpose slings.

Velocity Ratio

The ratio between the velocities of a chain block hand chain and the load. It is equivalent to the number of metres of hand chain overhauled to raise the load a distance of one metre.

WLL

W o r k i ng L o a d L i m i t .

Warning Beacon

A l am p t hat i s ca pa bl e o f e m i t t i ng a f l a s hi ng o r r o t a t i ng be a m of light through 360º in the horizontal

Winch

A s t a t i o na r y m o t or dr i v e n o r ha nd po w er e d hoi s t i ng m a chi ne having a drum around which is wound a rope used for hoisting, lowering or pulling a load.

W i n d Lo a d

The forces produced by the velocity of the wind, which is assumed to act horizontally.

Webbing

A pa r t o f a l i f t i ng s l i ng , e i t he r fl a t o r r ou nd, c om pr i s i ng a w ov e n nar r o w f a br i c, ge ne r a l l y o f a co a r s e w e a v e a nd multiple plies, the prime function of which is load be aring.

W h i p pi n g

See Serving .

Working Load Limit (WLL)

The maximum load, which an item of lifting equipment is designed to raise, lower or suspend as stated by equipment manufacturer.

Page 247 of 247

the