THE LIFTING & MECHANICAL HANDLING GUIDELINES

THE LIFTING & MECHANICAL HANDLING GUIDELINES Improving safety and effecting change through collaboration

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1

1. Preface 2

2. Responsibilities 3

2.1 Responsible Person (RP) 32.2 LOLER Appointed Person / LOLER Focal Point (LAP/LFP) 32.3 A Competent Person (CP) 3 2.4 Person in charge of lifting operation (PIC) 3 2.5 Lifting Team (LT) 3

3. Planning the Lift 4

3.1 Define the lift 43.2 Plan the Lift 43.3 Technical Support 53.4 Lifting Operation Risk Assessment 53.5 Finalising the Lift Plan and Lifting Operation Risk Assessment 5

4. Equipment and Personell 6

4.1 Selection of Lifting Equipment 64.2 Examination and Inspection of Lifting Equipment 64.3 Selecting Competent Personnel 64.4 Toolbox Talk (TBT) 64.5 Conducting the Lifting Operation 74.6 Learn and Record 7

5. Training and Competency 8

5.1 Personnel who undertake Lifting and Mechanical Handling Operations 8

6. Monitoring, Audit and Review 10

7. Summary 10

Appendix 1 11

Appendix 2a 12

Appendix 2b 17

Appendix 3a 24

Appendix 3b 25

Contents

Lifting and Mechanical Guidelines

02

Lifting and Mechanical Handling Incidents continue to occur, and they can result in serious injuries and even fatalities. Lifting operations must be properly planned, risk assessed and undertaken by competent personnel using appropriately selected and certified equipment to ensure they are carried out in a safe manner.

These guidelines are to assist in ensuring lifting and mechanical handling operations are undertaken safely and include;

• Roles and responsibilities• Supervision• Planning • Risk assessment• Training and competencies • Assessment of competence

Organisations must ensure that all personnel involved in lifting and mechanical handling operations clearly understand their roles and responsibilities. Where deficiencies in training and competence are identified the employer must take appropriate action to address the situation.

Everyone involved has specific responsibilities and must be able to demonstrate the required level of competency for the role and task assigned.

Step Change in Safety expects member organisations that are involved in lifting and mechanical handling operations to adopt these guidelines as a minimum standard. These guidelines continue to advocate that every lifting operation must have a lifting plan and that it is authorised by a Loler Appointed Person.

1. Preface

03

2.1 Responsible Person (RP)

Responsible Person (RP) has overall responsibility for the work activities. For example, this could be the Shift Supervisor, Base Manager, Project Engineer or Tool-pusher. The Responsible Person recognises or is advised of, the need for a lifting activity. The Responsible Person should then inform the Competent Person of the loads involved, location, timescales etc to allow the Competent Person to begin the planning process.

2.2 LOLER Appointed Person / LOLER Focal Point (LAP/LFP)

The LOLER Appointed Person / LOLER Focal Point1 must have an understanding of the LOLER and PUWER regulations and how they apply to lifting operations. They must have the practical skills and theoretical knowledge to plan lifting operations, undertake risk assessments and conduct toolbox talks. The LOLER appointed person will review and authorise lifting plans that have been written by a LOLER competent person. A site visit must be conducted by the LOLER appointed person prior to authorisation. The LOLER appointed person may or may not supervise the lifting operation but is the focal point of authority for all the technical aspects associated with a lifting operation. They must know their competency limitations, work within them and know when technical support is required. Only the LOLER Appointed person should authorise lifting plans.

2.3 A Competent Person (CP)

A Competent Person, (CP) must have the applied skills and theoretical knowledge to plan and risk assess lifting operations. This person must have the technical knowledge and operational experience to select the appropriate lifting equipment to be used, and plan how it should be used safely and within the equipment safe use parameters.It is important that they know their own competency limitations, work within them and know when technical support is required.

2.4 Person in charge of lifting operation (PIC)

The person in charge of lifting operation (PIC) has direct control of the lifting operation and the lifting team. This will be a member of the Lifting Team, in the case of a crane lifting operation this would normally be the Banksman.

2.5 Lifting Team (LT)

The Responsible Person will assign the members of the lifting team who will undertake the task together with the Person in Charge of lifting operation (PIC). They must ensure that team members have the correct competencies to enable them to complete the lift in a safe and controlled manner.

Each team member has the responsibility to know and work within their own level of competency to complete the job safely. They are required to attend and actively participate in toolbox talks, carry out pre-use and post-use inspections of lifting equipment and stopany operation if concerned about its safety.

The level of competency required to perform these roles are included in Section 5 of this document.

1 These titles may vary depending on Dutyholder.

2. Responsibilities

04

3.1 Define the lift

Identify Lifting Activity

The Responsible Person should identify or be informed of the need for lifting operations and inform the Competent Person. The Responsible Person should also provide details of the loads involved, their location, timescales etc., to allow the Competent Person to begin the planning process.

Determine Scope of Work

The Competent Person must begin the planning process by determining what has to be done, and the equipment required. This may require an initial lift plan, sketches, notes etc. If additional technical support is required, then this should be obtained before proceeding.

3.2 Plan the Lift

During the planning process, the normal hazards associated with lifting operations should be grouped together as common hazards (see appendix 1). The Duty Holder must ensure adequate control measures are in place to mitigate these common hazards. These control measures do not need to be included in the specific lifting operations risk assessment or discussed at the toolbox talk. The lifting operations risk assessment and the toolbox talk should then become more focussed on the lifting operation. The Duty Holder will still need to have these common hazards addressed in a documented risk assessment and within their safety management system identified how the operation of these control measures will be audited.

Some duty holders have systems in place to categorise a lifting operation in terms of its complexity, such as simple, complex and complicated. Such classification may be of assistance during the planning process and gives details of actions that are required, for example onshore lift plan approval. These systems are optional.

A lift plan should detail the step-by-step instructions and the equipment required to carry out the lifting operation.. If during this planning stage the hazards identified cannot be eliminated by the method detailed in the lifting plan or by existing control measures, they need to be addressed in a lifting operations risk assessment and mitigations identified.

Where a lifting plan already exists, the Competent Person must determine whether any changes are required. Any changes made must be documented in the reviewed lifting plan and risk assessment.

If lifting equipment is required to be lifted into place, then a lifting plan and risk assessment will be required if this activity is not already covered in the current Version of the lifting plan. A separate lifting plan and risk assessment will then be required for the positioning and removal of the equipment.

Where lifting equipment is manually handled into position, a manual handling, and where appropriate, a working at height risk assessment may be required.

3. Planning the Lift

05

3.3 Technical Support

The LOLER Appointed Person may identify the need for additional technical support. A technical review is undertaken by someone who has the necessary competencies to make an informed and impartial judgement on the lift plan. This can be another LOLER Appointed Person reviewing the lift plan or the involvement of a structural engineer to check the loadings on beams/ laydown areas. It is important that the LOLER Appointed Person acknowledges there will be limits to their competence and they are aware of all available technical support. 3.4 Lifting Operation Risk Assessment

Once the lift plan is complete, the Competent Person must identify all hazards that are not ‘common hazards’ (see appendix 1). Where such hazards remain, they must be addressed in a lifting operation risk assessment.

The Competent Person should avoid recording all the ‘common hazards and controls’ on the lifting operations risk assessment. These common hazards should have already been recognised as continuously re-occurring and must be eliminated or controlled by existing processes or procedures. This will then allow the lifting operation risk assessment to focus on the specific hazards associated with the lift. Following this stage, the lift plan and lifting operation risk assessment may require further technical review. Where a lifting operation risk assessment already exists, the Competent Person must determine whether any changes are required, any changes made must be documented.

3.5 Finalising the Lift Plan and Lifting Operation Risk Assessment

The Appointed Person must review and approve the lift plan and lifting risk assessment. Some duty holder procedures may require the lift plan and lifting operation risk assessment to be endorsed by a technical authority or management representative.

The methods described in the lift plan and control measures specified in the lifting operation risk assessment must be followed to ensure the lift is carried out in a safe and controlled manner.

3. Planning the Lift

06

4.1 Selection of Lifting Equipment

It is essential that the lifting equipment being used is suitable for the task, is certified, and visually checked for any defects etc before being used. The competent person must also take into consideration:

• The configuration that any item of equipment or accessory will be used and any subsequent effect this may have on the item

• Inherent risks to health and safety as a result of its use• The place where it will be used• Ergonomic risks

4.2 Examination and Inspection of Lifting Equipment

All lifting equipment and accessories shall have current certification and be subjected to in-use inspections to ensure continued integrity. The use of a colour code to identify equipment that has a current report of thorough examination is recommended and regarded as industry good practice.

All lifting equipment and accessories must be subjected to pre, in-use and post-use inspections to identify any defects. Where the personnel undertaking the lifting operations are also carrying out these inspections they must have received appropriate training to ensure they are competent to undertake these.

4.3 Selecting Competent Personnel

Only trained and competent personnel should be involved in lifting operations. Personnel should be trained, assessed and monitored as part of a Competency Scheme. Section 5 details the competency standards expected across the various sectors of the oil and gas industry.

Although the nominated Person in Charge of the lifting operation is responsible for ensuring the lifting operation is carried out in a safe manner, all personnel involved also have a responsibility for ensuring that the lift is carried out safely.

4.4 Toolbox Talk (TBT)

Prior to the start of all lifting operations, a lifting operation specific Tool Box Talk must be held. This will be in addition to any other Tool Box Talks held in relation to the overall task of which the lifting operation may only be a part of.

If possible, the TBT - or a relevant portion of the talk - should be held at the worksite, if conditions are suitable. Where the workplace has high noise, poor lighting, or is likely to be affected by poor weather conditions then a more suitable location needs to be found.

All personnel involved in the lifting operation must attend a TBT before the task starts. Covering a review of the lift plan, control measures identified in the lifting and task risk assessment and allocation of specific individual responsibilities. Confirmation must be sought that all team members understand and agree with the detail in the lift plan and risk assessments.

4. Equipment and Personnel

07

The TBT should be one that stimulates interest and maximises participation. The allocation of responsibilities will include the identification of the Person in Charge of the lifting operation. Appendices 3a and 3b provide examples of Toolbox Talk forms which are specific to lifting operations. If, after discussion, a change is required to the lift plan or lifting operation risk assessment the LOLER Appointed Person must approve and record any changes before the lifting operation can commence.

For deck lifting operations there may be existing lift plans. These will cover a range of lifting operations that can be carried out by each crane, in terms of the designated laydown areas and the loads that can be lifted. These documents should be available at the TBT and confirmation is required that they cover the lifting activities planned to be undertaken. If this is not the case, then either an existing lift plan and risk assessment will need to be amended, or a new lift plan and lifting operation risk assessment will be required.

4.5 Conducting the Lifting Operation

The lifting operation will be conducted following the agreed and approved lift plan, using current and industry good practice. It is important that lifting equipment is only used in accordance with the manufacturers operating instructions and these should be available and referenced as required.

As a job proceeds, it becomes natural for an individual’s sensitivity to risk to diminish. This is due to growing familiarity and the knowledge that the lifting operation is going according to plan. It is therefore vital that the process of evaluating risk is dynamic and that it is continuous throughout the entire lifting operation. Even seemingly small changes in circumstances can have a significant impact if their potential is not recognised in time. It is therefore, vital that a level of hazard awareness is always maintained. In circumstances where an unforeseen hazard appears, or an unforeseen potential hazard is identified, the lifting operation must be stopped when safe to do so. Contact the LOLER Appointed Person and if, after discussion, a change is required to the lift plan or lifting operation risk assessment the LOLER Appointed Person must record and approve any changes. A further Tool Box Talk must be held to ensure all team members are aware of and agree to the changes.

4.6 Learn and Record

Debrief and Learning Points (After Action Review)

The debrief and learning points should confirm that the job has gone according to plan or identify any issues that arose so that they can be recorded for future use.

Everyone involved in the lifting operation must have the opportunity to discuss and suggest any improvements to the lift plan. Any suggested changes will need to be reviewed by the LOLER Appointed Person and actioned as appropriate.

4. Equipment and Personnel

08

All personnel involved in lifting and mechanical handling operations must be trained and assessed as competent to the required standards. They will need to undergo regular formal assessments to ensure continued competence. Training and competence standards should follow recognised industry or national standards where they exist.

5.1 Personnel who undertake Lifting and Mechanical Handling Operations

In order to conduct safe lifting operations to today’s high standards, it is important that a process is in place which permits personnel to progress through the stages to become competent to undertake lifting operations, and to maintain this competence. It is recognised that lifting and mechanical handling competencies will differ across the industry. For example, lifting operations carried out by drilling contractors may involve different skills from those carried out by construction.

Personnel deemed competent may be required to use lifting equipment and accessories that they have had no formal training on. In this case it is the responsibility of the duty holder/employer to ensure that personnel are given adequate training, instructions and health and safety information in the use of such equipment.

In the case of ad-hoc personnel employed on short-term contracts, there must be a process in place to validate the competency of these personnel and, if necessary, update and refresh their skills and knowledge.

There are a number of training courses available for personnel who undertake lifting operations and those that plan lifting operations. OPITO or ECITB, for example, offer a full range of training and competency and assurance standards for personnel who undertake and plan lifting operations.

Categories of personnel who undertake lifting and mechanical handling operations and suggested training and competence assessments can be found on page 9.

5. Training and Competency

09

Stage

4Onshore

Assessment

Stage

3Onshore

Assessment

Stage

2Workplace

Stage

1Off the Job

ReassessmentEvery 2 years

RiggerOPITO Standard

Stage 3 Rigger

OPITO Standard competence assessment

Supervised Workplace

Development and completion of OPITO Rigger

logbook

Stage 1 RiggerOPITO Standard and Introductory training program

Personnel Undertaking Lifting Operations Using Portable Lifting

Equipment


OPITO Standard

Stage 3 Banksman

Slinger OPITO Standard

assessment


Development and completion

of OPITO logbook

Stage 1Banksman

SlingerOPITO Standard and Introductory training program

Crane Banksman and Slingers


Development and completion

of OPITO Drilling Rigger logbook

Stage 1 RiggerOPITO Standard and Introductory training program

Stage 3 Drilling Rigger

OPITO Standard competence assessment

ReassessmentEvery 2 yearsDrilling Rigger

OPITO Standard

Drilling Personnel undertaking

lifting operations which form part

of Routine Drilling Activities


Development

ECITB or OPITO technical

assessment

ECITB Technical standard training

course

Reassessment every 2 or 3 years

OPITO or ECITB

LOLER Appointed

Person


OPITO Standard and workplace or

simulator

Competence assessment

OPITO Standard


Development

Introductory Training Program OPITO Standard

Level 2 Offshore Crane Operator

Reassessment(Workplace or

simulator) Every 2 years

OPITO Standard

Competence assessment on

selected offshore Structural typeOPITO Standard


Development

Introductory Training Program OPITO Standard

Level 3 Offshore Crane Operator

Notes: This route is an alternative to a recognised Rigger qualification, eg S/NVQ Moving Loads / Diploma, it is not a replacement or equivalent.

The diagram above shows the key stages that an individual must pass through to achieve and maintain competency.

Stage 1 The first stage of all training comprises initial training and assessment. This is normally carried out at an onshore training establishment - in the chart shown above, this is identified as Stage 1. At the completion of Stage 1, the level of training is deemed sufficient for that person to conduct lifting operations under the direct worksite supervision of a competent person as part of their Stage 2 training.

Stage 2 Workplace supervised training and the practical application of the learning obtained in Stage 1. A logbook is normally used to record the completion of specific tasks for this workplace training.

Stage 3 A formal assessment of competency by an OPITO approved provider. This can be done on or off site.

Stage 4 This is a regular ongoing performance assessment to ensure that competency is maintained.

10

Lifting and Mechanical Guidelines

It is essential that the processes and procedures for the management of lifting operations are continually assessed to ensure they are being implemented correctly and remain suitable. The techniques employed to verify compliance should include simple spot checks and comprehensive audits.

To be effective, these verification activities should be carried out at sufficient intervals to provide assurance that safe lifting operations are being undertaken. All elements of the system from procedures and documents utilised to the actual practices employed at the worksite, should be covered. The verification activities should include;

a. Associated proceduresb. Actual working practicesc. Training, competency and skill developmentd. Equipment suitabilitye. Organisational structuref. Recording and implementation of lessons learned

The findings of the verification process should be cascaded to all those within the organisation with roles and responsibilities for lifting operations.

6. Monitoring, Audit and Review

These guidelines offer guidance on the elements of a robust system incorporating minimum standards. Regardless of the system used, the most important factors are;

• Competency of personnel carrying out the lifting operation is sufficient for the task• Lifts are planned to ensure hazards have been identified and risks managed • Lifts are carried out with suitable equipment, in accordance with a lifting plan• Hazard identification is dynamic and applied throughout the entire lifting operation, if

conditions change, the hazards, risks and controls are reassessed• Lessons learned are taken into account when planning future lifts

7. Summary

11

Common Hazards

Appendix 1

EVENT HAZARD CONTROL MEASURES

Failure of lifting equipment through overload

Dropped objects All lifting operations require a lifting plan and this has to be authorised by the appointed Competent Person

Failure of lifting equipment through incorrect use

Dropped objects All personnel using lifting equipment have to receive training, be assessed as competent and receive reassessments as per industry standards. Instructions for the safe use of lifting equipment to be made available and followed

Failure of lifting equipment through damage or deterioration

Dropped objects Only lifting equipment that has current certification and colour coding can be used. Portable lifting equipment is controlled through a rigging loft. Documented in-service inspections are undertaken on all lifting equipment. Pre use checks are undertaken on all lifting equipment

Incorrect positioning of lifting equipment

Dropped objects To be positioned only by competent personnel. Details of the positioning to be included in a lifting plan

Failure of lifting equipment suspension points

Dropped objects Lifting equipment only to be attached to certified steelwork or steelwork which has been assessed as fit for purpose

Swinging load Struck by load The use of tag lines – to be discussed at toolbox talk. No touching of load until load is below waist height – to be discussed at toolbox talk

Personnel enter danger zone Struck by load Effective barriers to be in place – discussed at toolbox talk

Positioning, operating and removing lifting equipment at height

Fall from height Duty holder procedures to satisfy working at height regulations

Manual handling Muscular strain Duty holder procedures to satisfy manual handling regulations

Undertaking lifting operation Slips, trips and falls

Duty holder housekeeping rules, inspection of worksite as detailed in toolbox talk

12

Appendix 2a

Deck Lifting Plan

Site Area / Location

Offshore Platform Designated landing areas: Refer to plot plans

Lifting Plan Number Risk Assessment Number

DLP-001 DLRA-001

Author Revision and date

Deck Foreman Rev A1 27/05/2019

2.0 Lifting Operations Description

The use of the East Platform Crane for lifting, transporting, lowering and final positioning CCU’s, IBC’s and POU’s between platform designated landing areas.

All CCU’s IBC’s & POU’s shall have a fixed 5 leg lifting bridle

Definitions: CCU – Cargo Carrying Unit. IBC – Intermediate Bulk Container. POU – Portable Offshore Unit.

3.0 Weight of Load

• Complete as appropriate

Variable weights but within the capacity / SWL & radius of the crane on a single fall & double fall configuration. The variable load weights shall also be within the global loading capacities of each individual designated inboard landing area.

Actual Calculated

4.0 Task Specific Pre-requisites: (use continuation sheet if required)

All Lifting Operations require the following to be considered but this list is not exhaustive.

weight, size, shape and centre of gravity of loadmethod of slinging/attaching/detaching the loadavailability of approved lifting points on loadproximity hazards, obstructions, path of load

Method(s) of Communication to be used:

Radio Verbal Hand Signals

Task Details Step by Step Individual Responsibilities

Steps Stage 1 – Position the crane boom above the load

Load Handler to inspect the load to ensure there are no possible dropped objects, which may become dislodged when the load is lifted.

Load Handler1.

1.

2.

2.

Under instruction from the Banksman, the Crane Operator shall position the east crane boom directly over the load ensuring the load line is plumb.

Banksman

Stage 2 – Connect cargo handling pennant to the load

The Banksman shall instruct the Crane Operator to lower down on the load line until the hook of the cargo-handling pennant has reached a suitable height / position to attach the master link of the load-lifting bridle then stop the crane.

Banksman

The Load Handler shall now connect the master link of the load-lifting bridle to the hook of the crane cargo-handling pennant. Load Handler

TO BE COMPLETED BY THE COMPETENT PERSON1.0 Details

conflicting tasks in area overturning/load integrity/need for tag linesnumber of personnel required for taskenvironmental conditions including weather

Steps

13

Appendix 2a

Deck Lifting Plan

1.

1.

2.

3.

4.

5.

1.

2.

3.

4.

1.

2.

3.

4.

2. The Banksman shall now conduct a visual check of the load to ascertain that the load balance and centre of gravity is correct.

The Banksman shall instruct the Crane Operator to slowly lift-up on the load line until a minimal amount of tension has been appliedto the load-lifting bridle, then stop the crane.

The load-lifting bridle shall now be visibly checked for any anomalies such as twists or kinks.

On completion of the check, the Banksman shall instruct the Crane Operator to slowly lift-up on the load line until the load is just clear of deck level, then stop the crane.

On completion of the check, the Banksman shall instruct the Crane Operator to slowly lift-up on the load line until the load is clear of the landing area (Banksman to be vigilant in his observation for any potential snagging points).

Once the load is clear of the landing area the Banksman shall hand over control of the load to the Crane Operator.

The Crane Operator shall now transport the load to a safe holding area and await further instructions from the Banksman.

Stage 5 – Land the load at the laydown area

Under the instruction of the Banksman, the Crane Operator shallposition the load directly above the laydown area then stop the crane.

Banksman / Crane Operator


The Banksman shall now instruct the Crane Operator to slowly lower down on the load line (Banksman to be vigilant in his observation for any possible snagging points) until the load has reached a point below waist height then stop the crane.

Banksman

Banksman

Banksman

Banksman

Banksman

Crane Operator

Banksman / Load Handler

The load handler can now position the load into the correct orientation for lowering as required. Load Handler

Having completed this, the Banksman shall instruct the Crane Operator to slowly lower down on the load line until the load has landed on the designated lay down area, then stop the crane.

Banksman

Stage 6 – Disconnect cargo handling pennant from load

Banksman now instructs the Crane Operator to slowly manoeuvre the crane until the hook of the cargo handling pennant has reached a suitable height / position alongside the load to allow it to bedisconnected from the master link of the load lifting bridle, then stop the crane.


The hook of the cargo-handling pennant can now be disconnected from the master link of the load-lifting bridle. Load Handler

Under the guidance of the Banksman, the Crane Operator shall now slowly raise up on the load line until the empty hook of the cargo-handling pennant is clear of the landing area.


The Banksman shall now instruct the Crane Operator to stand by and await further instructions. Banksman

Steps

Stage 3 – Apply tension to the load-lifting bridleSteps

Stage 4 – Transportation of the loadSteps

Steps

14

Appendix 2a

Deck Lifting Plan

5.0 Additional Input

Additional Technical Support Required (where unknown load factors exist and cannot be verified i.e. uncertified steel) i.e. if transferring from the craneto portable rigging equipment.

6.0 Lifting Equipment & Accessories to be used (Specify type and SWL)

Platform 40 Tonnes SWL East Crane

8 Tonne SWL Cargo Handling Crane Pennant

15 Tonne SWL Cargo Handling Crane Pennant

7.0 Lift Drawing(s) / Sketches

8.0 Common Hazards Specific to Lifting Operations

Event Hazard Control Measures

Failure of Lifting Equipment through overload

Dropped ObjectsDetermine the weight of the load and use appropriately rated rigging equipment and accessories for the slinging method used

Failure of Lifting Equipment through incorrect use

Dropped ObjectsAll personnel using lifting equipment must have received training and be assessed as competent. Instructions for the safe use of lifting equipment to be made availableand the Lift Plan to be followed

Failure of lifting equipment through damage or deterioration Dropped Objects

Only lifting equipment that has current certification and colour coding can be used.Portable lifting equipment is controlled through the rigging loft. Documented in-service inspections are undertaken on all lifting equipment. Pre use checks are undertaken on all lifting equipment

Incorrect positioning of lifting equipment Dropped Objects

To be positioned only by competent personnel. Details of the positioning to be included in the Lifting Plan

Failure of lifting equipmentsuspension points

Dropped ObjectsLifting equipment only to be attached to certified steelwork or steelwork which has been assessed as fit for purpose

Swinging load Struck by loadEnvironmental conditions to be considered. The use of tag lines – to be discussed at toolbox talk. No touching of load until load is below waist height – to be discussed at toolbox talk

Personnel enter danger zone Struck by load Effective barriers to be in place – discussed at toolbox talk. Be aware of adjacent worksites. Ensure load route is free of personnel before lifting commences


Fall from height Client & WGPSN procedures to satisfy working at height regulations

Manual Handling Muscular strain Client & WGPSN procedures to satisfy manual handling regulations

Undertaking Lifting operations Slips, trips, falls Client & WGPSN housekeeping rules to be adhered to, inspection of worksite as detailed in Tool Box Talk, awareness of surroundings and available escape routes

Yes

Structural Department input for the use of uncertified steelwork.

No

15

9.0 Non-common hazards which may apply to the lifting operation to be addressed in the Lift Plan (from initial assessment)

10.0 Risk Assessment

Hazard (Consider all phases of the operation from pick up to lay down of load). This list is not exhaustive.

Applicable Eliminated by the method detailed in the Lift Plan

Unverified weight of load

Fragile load requiring additional protection during the lift or at lay down

Load has high centre of gravity or is unstable (delete as applicable)

Potential for loss of load integrity

Attachment point has sharp edges (delete as applicable)

Load has no dedicated lifting points

There are no certified suspension points for the lifting equipment to be used for cross hauling from the crane

Lifting of chemicals

Restricted headroom or confined work area

Tag lines required, hands free tools to be used

Potential communications difficulties

Lift path is over hazardous live process plant / materials (delete as applicable)

Lift path is in close proximity to permanent obstacles (delete as applicable)

Obstructions in pick up or lay down area

Lay down area not adequate in terms of size or load bearing ability

Lay down area not within operating limits / radius of lifting equipment

Non-essential personnel can potentially enter the area below the lifting operation

Designated safe areas are identified ensuring ricochet and deflected hazards are considered and correctly managed

Other: Specify

Other: Specify

Other: Specify

Other: Specify

Other: Specify

Location:

WHERE APPLICABLE HAZARDS THAT CANNOT BE ELIMINATED BY THE LIFTING METHOD DETAILED IN THE LIFTING PLAN THEN A LIFTING OPERATIONS SPECIFIC RISK ASSESSMENT MUST BE COMPLETED.

Yes / No Yes / No

Task Based Risk Assessment

Task Activity:

Groups Affected: ServicesPersonnel Involved: Deck Crew and Crane Operator

Date: 27/05//2019Assessor: D. Foreman

*Permanent Total Disability

= Low Risk / Proceed

CONSEQUENCES INCREASING LIKELIHOOD

RA Number:

Sheet 1 of 1

SEVERITY

People Assets Environment Reputation Never heard ofin the industry

Heard of in the industry

Incident has occurred in our

company

Happens several times a

year in our company


year in a location

A

1

2

3

4

5

B C D E

No health effect / injury

No damage No effect No impact

Slight health effect / injury

Slight damage Slight effect Slight impact

Major health effect / injury

Localised Damage

Localised effect Considerable impact

PTD* or 1 to 3 fatalities

Major damage Major effect National impact

Multiple fatalities

Extensive damage

Massive effect International impact

= Medium Risk / Do not proceed contact onshore support

= High Risk / Do not proceed contact onshore support

Appendix 2a

Deck Lifting Plan

16

Appendix 2a

Deck Lifting Plan

11.0 Review and Approval

12.0 Workforce Declaration

13.0 Debrief and learning points (if applicable)

Hazard

Authorised by Appointed Person / LFP

Person Responsible at Worksite for the Lifting Operation:

Authorised by TA if Categorised Complex

WORKFORCE SIGNATURES

ControlsINITIAL RISK RESIDUAL RISK

Step No

Description of task step

Name: Date: Signature:Position:


Name:

Name

Comments:

All members of the workforce must read and sign this declaration indicating that they have read, understood and will comply with the Toolbox Talk, Risk Assessment and Lifting Plan. No deviations from the plan will take place without the approval of the competent person who has the required level of training and has been appointed. If changes are required involving the Lifting Operation then the job must STOP, the competent person will be informed, the job re-assessed, and a new Lifting Plan and Risk Assessment will be agreed upon and implemented if required.

Date:

Date

Signature:

Signature Name DateSignature

Position:

Hazard description & effect

Who or what might be harmed

Control measures and/or recovery measures

SEVERITY

LIKELIHO

OD

RISK RA

TING

SEVERITY

LIKELIHO

OD

RESIDU

AL

RISK RATIN

G

17

Appendix 2b

LOLER Lift Plan and Hazard Identification

Site Area / Location

Offshore Platform Level 2 Module NW02

Lifting Plan Number Risk Assessment Number

PRLP123 PRRA123

Author Revision and date

L.F.Pointer Rev A1 06/11/2019

2.0 Lifting Operations Description

Remove and replace Valve BV1652 and support associated pipework.

3.0 Weight of Load

Confirmation in writing from the Structural Department that the uncertified steelwork to be used to support loads is fit for purpose.All process and instrument isolations to be confirmed and shown at TBT StageSpill kits to be available at the work site

Valve weight 1065kgs, Pipework north side 300kgs, pipe work south side 700kgs Actual / Calculated(Delete as appropriate)

4.0 Task Specific Pre-requisites: (use continuation sheet if required)

All Lifting Operations require the following to be considered but this list is not exhaustive.

weight, size, shape and centre of gravity of loadmethod of slinging/attaching/detaching the loadavailability of approved lifting points on loadproximity hazards, obstructions, path of load

Method(s) of Communication to be used:

Radio Verbal Hand Signals

Task Details Step by Step Individual Responsibilities

Steps Stage 1 – Rig up for the task

A podium stairway can be used to access all overhead steelwork to allow attachment / detachment of the rigging equipment. InfoINFO

1.

2.

3.

4.

To the structural beam directly above the valve attach a 3te SWL Universal Beam Clamp, using a 3.25te WLL shackle hang a 2te SWL x 6m HOL Chain Block. This will be LP1

To the structural beam 1.5 metres to the west of the above beam and in direct line with the valve attach a 3te SWL Universal Beam Clamp, using a 3.25te WLL shackle hang a 2te SWL x 6m HOL Chain Block. This will be LP2

Riggers

Riggers

Riggers

To the structural beam 1.5 metres to the west of the above beam and in direct line with the valve attach a 3te SWL Universal Beam Clamp, using a 3.25te WLL shackle hang a 2te SWL x 6m HOL Chain Block. This will be LP3

To the structural beam directly above the valve and 500mm to the north attach a 3te SWL beam clamp and from this hang a 1te SWL x 4 metre wire rope sling using a 3.25te WLL shackle. To the lower eye of this sling attach a 1.36te WLL x 629mm hook / hook turnbuckle. This will be SP1

TO BE COMPLETED BY THE COMPETENT PERSON1.0 Details

conflicting tasks in area overturning/load integrity/need for tag linesnumber of personnel required for taskenvironmental conditions including weather

18

Appendix 2b


5.

7.

8.

9.

INFO INFOSee Sketch 1 Plan & Sketch 1 & 2 Elevation in Section 7 for layout

1.

2.

2.

3.

4.

5.

6.

7.

8.

6. To the structural brace to the south of the valve attach a 1te SWL x 3 metre wire rope sling in the double wrap and choke configuration to the free eye of the sling attach a 750kg SWL lever hoist This will be PP1

To the structural beam directly above the valve and 500mm to the south attach a 3te SWL beam clamp and from this hang a 1te SWL x 4 metre wire rope sling using a 3.25te WLL shackle. To the lower eyeof this sling attach a 1.36te WLL x 629mm hook / hook turnbuckle This will be SP2

Riggers

To the welded pipe support to the north of the valve at deck level cradle a 1te SWL x 2 metre wire rope sling to the eyes of the sling attach a 750kg SWL lever hoist. This will be PP2 Use rubber and wooden packers to protect the sling

Riggers

Roughly 1 m from each side of the valve attach a 2te SWL fibre sling in the double wrap and choke configuration, connect PP1 & PP2 to the loose eyes and take the strain

Riggers

Have a 2te SWL steerable trolley available on the walkway below LP3 to receive the valve

Riggers

Stage 2 – Support the north / south pipe work

500mm south of the valve double wrap and choke a 1te SWL x 2m Wire rope sling attach the load hook of SP1 turnbuckle to the free eye and take up the tension

Riggers

1.Sling the valve using 1 x 2te SWL fibre sling in the double wrap and choke method at each flange bring the two free eyes together and attach to a 3.25te WLL shackle and a 6.1te WLL Master Link

Riggers

500mm North of the valve double wrap and choke a 1te SWL x 2m Wire rope sling attach the load hook of SP2 turnbuckle to the free eye and take up the tension

Riggers

Attach the load hook of LP1 to the master link and take the weight

Allow the fitters to access the flanges and remove all but 4 bolts

Riggers

FittersOnce the bolts have been removed take some weight on PP1 & PP2 to open the flanges and free the valveOnce flanges are free remove the remaining bolts and lift on LP1 to confirm the valve is free to lift

Connect the load hook of LP2 to the master link and begin to cross haul the valve once LP2 has all the weight release LP1 from the masterlink and connect LP3 to the master link and continue the cross haul

Riggers

Riggers

Fitters / Riggers

Once all the weight is on LP3 remove LP2 from the master link. Lower off on LP3 to place the valve on the pre-positioned trolley; once it touches down STOP and using 2 x ratchet straps secure thevalve to the trolley. Once secure lower off completely and remove LP3 load hook from the master link

Riggers

Transport the trolley and valve to the crane landing area for the deck crew to pick up using their separate deck lift plan. Leave the rigging attached for their use

Riggers / Deck Crew

Steps

Stage 3 – Remove the valveSteps

19

Appendix 2b


1.

4.

2.

3.

6.

7.

8.

9.

1.

2.

5. As the valve approaches installation position alert the fitters and allow them access to the worksite.

Check the valve is correctly slung as per this LP and secured to the trolley then transport It to the worksite below LP3.

Attach the load hook of LP3 to the master link and take the weight. Release the ratchet straps and make the valve free to lift.

Attach the load hook pf LP2 to the master link and then pick up on LP3 and begin to cross haul.

When the weight is all on LP2 release LP3 load hook from the master link and connect the load hook of LP1 to the master link and continue the cross haul.

Under guidance from the Fitters manoeuvre the chain blocks to place the valve in the installation position where bolts can be inserted.

The 2 x pull lifts may need to be adjusted to allow the fitting of the gaskets adjust as required.

Once the fitters are happy and all the bolts have been fitted release the two pull lifts to allow the bolts to be correctly tightened.

Once all the bolts have been correctly tightened lower on LP1 & LP2 slowly to ensure stability. Then lower off on SP1 & SP2 before lowering off completely on LP1 & LP2.

Stage 5 – De-Rig

Remove all rigging and return it to the Rigging Loft for inspection and sign in.

Tidy worksite of all tools and rubbish.

Riggers

Riggers / Fitters

Riggers / Fitters

Riggers / Fitters

Riggers

Riggers

Riggers

Riggers

Riggers

Riggers

Work Group

Steps

Stage 4 – Install the new valveSteps

5.0 Additional Input

Additional Technical Support Required (where unknown load factors exist and cannot be verified i.e. uncertified steel) i.e. if transferring from the craneto portable rigging equipment.

6.0 Lifting Equipment & Accessories to be used (Specify type and SWL)

2 x 3te SWL Universal beam Clamps

2 x 2te SWL x 6M HOL Chain Blocks

1 x 1te SWL x 2m IWRC Wire rope slings

3 x 3te SWL S2A beam clamps


2 x 1.36te WLL x 629mm hook / hook turnbuckles

5 x 3.25te Safety Pin Bow Shackles


2 x 750kg SWL Lever hoists

2 x 2te x 3m Fibre slings 2 x 1te WLL x 3m Ratchet straps 2te WLL steerable trolley

Yes

Structural Department input for the use of uncertified steelwork.

No

20

Appendix 2b


Stage 4 – Install the new valveSteps7.0 Lift Drawing(s) / Sketches

THE ABOVE THREE SKETCHES ARE NOT TO SCALE

21

Appendix 2b

LOLER Lift Plan and Hazard Identification8.0 Common Hazards Specific to Lifting Operations

Event Hazard Control Measures

Failure of Lifting Equipment through overload

Dropped ObjectsDetermine the weight of the load and use appropriately rated rigging equipment and accessories for the slinging method used.

Failure of Lifting Equipment through incorrect use

Dropped ObjectsAll personnel using lifting equipment must have received training and be assessed as competent. Instructions for the safe use of lifting equipment to be made availableand the Lift Plan to be followed.

Failure of lifting equipment through damage or deterioration Dropped Objects

Only lifting equipment that has current certification and colour coding can be used.Portable lifting equipment is controlled through the rigging loft. Documented in-service inspections are undertaken on all lifting equipment. Pre use checks are undertaken on all lifting equipment.

Incorrect positioning of lifting equipment Dropped Objects

To be positioned only by competent personnel. Details of the positioning to be included in the Lifting Plan.

Failure of lifting equipmentsuspension points

Dropped ObjectsLifting equipment only to be attached to certified steelwork or steelwork which has been assessed as fit for purpose.

Swinging load Struck by loadEnvironmental conditions to be considered. The use of tag lines – to be discussed at toolbox talk. No touching of load until load is below waist height – to be discussed at toolbox talk.

Personnel enter danger zone Struck by load Effective barriers to be in place – discussed at toolbox talk. Be aware of adjacent worksites. Ensure load route is free of personnel before lifting commences.


Fall from height Client & WGPSN procedures to satisfy working at height regulations.

Manual Handling Muscular strain Client & WGPSN procedures to satisfy manual handling regulations.

Undertaking Lifting operations Slips, trips, falls Client & WGPSN housekeeping rules to be adhered to, inspection of worksite as detailed in Tool Box Talk, awareness of surroundings and available escape routes.

9.0 Non-common hazards which may apply to the lifting operation to be addressed in the Lift Plan (from initial assessment)

Hazard (Consider all phases of the operation from pick up to lay down of load). This list is not exhaustive.

Applicable Eliminated by the method detailed in the Lift Plan

Unverified weight of load

Fragile load requiring additional protection during the lift or at lay down

Load has high centre of gravity or is unstable (delete as applicable)

Potential for loss of load integrity

Attachment point has sharp edges (delete as applicable)

Load has no dedicated lifting points

There are no certified suspension points for the lifting equipment to be used for cross hauling from the crane

Lifting of chemicals

Restricted headroom or confined work area

Tag lines required, hands free tools to be used

Potential communications difficulties

Lift path is over hazardous live process plant / materials (delete as applicable)

Lift path is in close proximity to permanent obstacles (delete as applicable)

Obstructions in pick up or lay down area

Lay down area not adequate in terms of size or load bearing ability

Lay down area not within operating limits / radius of lifting equipment

Other: Specify

Other: Specify

Other: Specify

Other: Specify

Other: Specify

WHERE APPLICABLE HAZARDS THAT CANNOT BE ELIMINATED BY THE LIFTING METHOD DETAILED IN THE LIFTING PLAN THEN A LIFTING OPERATIONS SPECIFIC RISK ASSESSMENT MUST BE COMPLETED.

Yes / No Yes / No

22

Appendix 2b

LOLER Lift Plan and Hazard Identification10.0 Risk Assessment

Location: Remove and replace Valve BV1652 and support associated pipework.

PRRA123 Task Based Risk Assessment

Task Activity:

Groups Affected: Maintenance, ProductionPersonnel Involved: Riggers, Fitters

Date: 06/11/2019Assessor: L.F.Pointer

*Permanent Total Disability

= Low Risk / Proceed

CONSEQUENCES INCREASING LIKELIHOOD

RA Number:

Sheet 1 of 1

SEVERITY

People Assets Environment Reputation Never heard ofin the industry

Heard of in the industry

Incident has occurred in our

company


year in our company


year in a location

A

1

2

3

4

5

1.

2

1

C2

C1

C2

C1

2

1

B

A

L

L

B C D E

No health effect / injury

No damage No effect No impact

Slight health effect / injury

Slight damage Slight effect Slight impact

Major health effect / injury

Localised Damage

Localised effect Considerable impact

PTD* or 1 to 3 fatalities

Major damage Major effect National impact

Multiple fatalities

Extensive damage

Massive effect International impact

= Medium Risk / Do not proceed contact onshore support

= High Risk / Do not proceed contact onshore support

Hazard ControlsINITIAL RISK RESIDUAL RISK

Step No

Description of task step

Valve removal

People All personnel must wear appropriate PPE

Spill kits on worksite, caps on all valves once removed

AssetEnvironment

Reputation

Spill ofhydrocarbons

Hazard description & effect

Who or what might be harmed

Control measures and/or recovery measures

SEVERITY

LIKELIHO

OD

RISK RA

TING

SEVERITY

LIKELIHO

OD

RESIDU

AL

RISK RATIN

G

11.0 Review and ApprovalAuthorised by Appointed Person / LFP

Person Responsible at Worksite for the Lifting Operation:

Authorised by TA if Categorised Complex



Name:

Comments:

Date: Signature:Position:

23

Appendix 2b


12.0 Workforce Declaration

13.0 Debrief and learning points (if applicable)

WORKFORCE SIGNATURES

Name

All members of the workforce must read and sign this declaration indicating that they have read, understood and will comply with the Toolbox Talk, Risk Assessment and Lifting Plan. No deviations from the plan will take place without the approval of the competent person who has the required level of training and has been appointed. If changes are required involving the Lifting Operation then the job must STOP, the competent person will be informed, and the job re-assessed, and a new Lifting Plan and Risk Assessment will be agreed upon and implemented if required.

DateSignature Name DateSignature

24

Appendix 3a

Toolbox talk card for a deck lifting operation

Installation / Location: Work Order / Permit Number:: Date:

Task

Persons allocated the responsibility and details of any additional control

measures

Name ofPerson

1. Discuss the specific lifting operations to be undertaken and confirm they are covered by existing lifting plans and lifting operations risk assessments. Should this not be the case do not undertake the lifting operation and contact the competent person

Person leading the toolbox talk to confirm this with all

2. Confirm all team members are familiar with the appropriate lifting plans and lifting operations risk assessments. If not work through these documents

Person leading the toolbox talk to confirm this with all

3. Does the weather or other environmental conditions create any additional hazards? If yes can suitable control measures be put in place or if not do not undertake the lifting operation

List the additional control measuresDoes everyone agree with these?

4. Names of personnel involved in the lifting operation:• Banksman• Crane Operator• Load Handler

5. Are tag lines required and who will attach them Name of person

6. Check the laydown areas for any additional hazards, identify and implement the control measures to address these hazards

Name of nominated person and detail any control measures

7. The route the load will take to be checked for any hazards, identify and implement the control measures to address these hazards

Name of nominated person and detail any control measures

8. Check condition of load for potential dropped objects Name of nominated Person

9. The pre use checks of the crane Crane Operator to undertake

10. The pre use checks and suitability of the lifting accessories Name of nominated Person

11. Check personnel are out of the area and barriers are put in place

Name of nominated Person

12. Are all radio batteries fully charged and spare batteries available?

All

13.What is the method of communication in the event of radio failure?

14. Supervision of any trainee Allocate supervisor

15. Any new team members Allocate a buddy

16. Will hands free lifting be undertaken? If not ensure no contact with the load unless it is below waist height

Load Handlers/Slingers

Tool Box Talk Attendees

TBT LEAD 6

1 7

2 8

3 9

4 10

5 11

25

Appendix 3b

Toolbox talk card for a Lifting Operation using Portable Lifting Equipment

Task

Persons allocated the responsibility and details of any additional control

measures

Name ofPerson

1. Discuss at the worksite (where possible), the lifting plan or the relevant part of the lifting plan that this tool box talk covers

Person leading the tool box talk

2. Ensure everyone agrees with the lifting plan and that it covers the full scope of the lifting operation to be undertaken. If not, contact the appointed Competent Person

Toolbox Talk Leader

3. Where there is a Lifting Operations Risk Assessment for the lifting operation discuss the content and implement the required control measures

All

4. Are there any site specific, SIMOP’s or weather-related hazards that have not been identified in the lifting plan or risk assessment? If there are any additional hazards identified agree required control measures prior to commencing the work

AllAdditional Control Measures

5. Allocate specific tasks to the team members Team Members

6. Name of Person in Charge of the Lifting Operation

7. Is anyone else giving support to the lifting operation Name and details

8. Walk the route the load will take to ensure there are no additional hazards. If there are any additional hazards identify and implement the control measures

Allocate to a team memberDetail the additional control measuresDoes everyone agree with these?

9. Undertake pre use checks of the lifting accessories, the lifting equipment and their anchor points

Allocate to team member

10. Check the condition of the load and for the potential of dropped objects


11. Check unauthorised personnel are out of the area and barriers are in place


12. Identify the method of communication that will be used during the lifting operation and check correct operation

All

13. Supervision of any trainees Allocate supervisor

14. Any new team members Allocate buddy

15. Where applicable have the following been addressed: Required isolations / inhibits Manual Handling Working at Height Confined Space Others (specify)

Tick where applicable

Tool Box Talk Attendees

TBT LEAD 6

1 7

2 8

3 9

4 10

5 11

Installation / Location: Work Order / Permit Number:: Date:

Revision August 2019

des

igne

d b

y fo

yer

grap

hics

3rd Floor

The Exchange 2

62 Market Street

Aberdeen

AB11 5PJ

01224 577268

[email protected]

www.stepchangeinsafety.net

Documents

THE LIFTING & MECHANICAL HANDLING GUIDELINES