Lifting, Stacking Procedure and Site Layout Area for Stacking of Prefab Piles

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Lifting & Stacking Procedure

TABLE OF CONTENTS

1. Introduction
1.1 Purpose 5
1.2 Scope 5
1.3 Definition 5
2. Roles and Responsibilities 7
3. Lift Planning and Execution 8
3.1 Defining the lift 8
3.2 Planning 13
3.3 Execution 14
3.4 Reacting to Change Conditions 14
3.5 Learn and Record 15
4. Application and Step-Out Approval 15
APPENDIXES
Appendix 1, Risk Matrix 16
Appendix 2, Sample Lift Plan 17
Appendix 3, Appendix 3, Site Plan Warri Stacking Area 18

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Introduction
1.0 Purpose

This document provides the procedure to be used for crane operational practices and approved technical
procedure to be followed in the stacking of piles at the Warri Fabrication yard before they are later
transported to the final driving site (Tunu, Benisede, Opukushi, and Ogbotobo)

1.1 This document also includes the controls to be observed during the pile stacking process.

LIST OF EQUIPMENTS/MATERIALS FOR STACKING WORK

 Crawler Crane 60 Tons capacity. 1 Pcs.

 Grove Crane 35 Tons capacity. 2Pcs.

 Roller compactor 1Pcs

 Wood Spacers Lots

 Sling wires Lot

 Shackles Lot

 Safety latch and other load lifting accessories.

.
The key to safe crane operation is having qualified personnel using the correct equipment in a safe manner.
This procedure will outline the issues relating to the selection of the correct people for the task. It will
describe the operational practices to be used by these people as part of a safe and effective crane and
rigging program.

1.2 Scope

This procedure applies to all lifting operations. The lift planning process describes the systematic
assessment of important load factors and site factors. It is as applicable to “simple” routine lifts as well as
”heavy” non-routine lifts. Planning a non-routine lift requires considerable effort. In a lift determined to be
non-critical, many of the elements can be determined "by inspection"; and the depth involved in a non-
routine lift will not be required. Nevertheless, the planning process must be followed.
This procedure prohibits a person from riding or travelling on the load, lifting hook, sling, platform or other
lifting medium.

1.3 Definition

Terminology specific to this document is given in the table below:

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Net Capacity
The net capacity is the gross crane capacity minus deductions. The deductions differ from
manufacturer to manufacturer as well as between crane types.
Deductions normally are:
Weight of main hook block
Weight of slings and rigging
Weight of auxiliary hook block
Weight of all wire rope from boom tip and the block
Weight of any stowed jib
Gross Capacity
The gross capacity is the capacity shown in the crane’s load or capacity charts.
Lift Planner
The gross capacity is the capacity shown in the crane’s load or capacity charts.
A person who has appropriate practical and theoretical knowledge and experience of the lifting operations to
enable him to prepare a full working lift plan and who is approved by the lifting equipment engineer.

Lifting Engineer (surveyor)

A person from a third party certification company who has the appropriate practical and theoretical
knowledge and experience of the lifting equipment to be thoroughly inspected as will enable him to detect
defects or weaknesses and to assess their importance in relation to the safety and continued use of the
lifting equipment.

2.0 PROCEDURES FOR STACKING OF PILES

The Warri fabrication yard, where the Piles are being stacked being a sand filled/sandy area is first of all
compacted with a roller compacting machine to reduce the settlement of the sand due to piles self-weight
when the piles are stacked on it

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 i. The compaction of the area where the piles is to be stacked is done alternately with wetting of the
area with water to ensure maximum compaction of the area and to reduce ground settlement on
stacking of the piles.

ii. The wood spacers are positioned just beside the point where the lifting hooks are positioned on the
piles.

iii. The piles are stacked in accordance to their age and length i.e older piles are stacked below new
piles and only piles of the same length are stacked on one another.

i. Care is taken to ensure that the wood spacers are placed on the same column position as the piles
are stacked, this is to ensure that the point of pile load transfer to the ground is at a straight line,
thereby preventing uneven stress developing in the stacked piles which may cause cracking of the
piles.

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 i. Piles of age 14days and above can be stacked to maximum height i.e 6 layers/columns for 360mm X
360mm piles and 5 layers/column for 440mm X 440mm piles.

3.0 GENERAL AND SAFETY PRECAUTIONS

 Permit to work process must be adopted for the pile stacking operation.

 Equipment and materials to be used for pile stacking operation must be checked thoroughly every

morning by competent personnel before they are engaged in the work.

 Only competent and experienced riggers, crane operators, supervisors etc should be engaged in the

pile stacking work.

 The area of work should be cordoned off to prevent anybody walking under suspended loads.

 Slings wires, shackles should be checked visually for any sign of twist bend or stress periodically

and should be replaced once any of this is noticed.

 Care should be taken to ensure that the safe working load of the equipment is not exceeded at any

point during the stacking operation

 A safety officer must always be present throughout the pile stacking operation.

4.0 ROLES AND RESPONSIBILITIES

Project Manager
Shall identify the need for a crane based on his/her work scope requirement.
Shall identify lifting parameters needed to execute the work.
shall constantly monitor the approved plan and identify improvement for future work.

HSE Personnel
Shall carry out risk assessment and ensure that the crane and the slings are certified and upto date.
Shall ensure tool box meeting and safety briefing is carried out

Lifting Engineer
Shall review and approve lifting plan and operation and also constantly monitor the approved plan and
identify improvement for future work.

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 Shall co-ordinate and control all aspects of lifting operations on site.

Crane Operator
Shall control the crane operations as per approved lift plan.
Shall participate in JHA/risk assessment/toolbox talk for the lift
Shall perform pre-use crane inspections.
Shall maintain crane operation logbook comprising manuals, pre-use inspection lists, crane/lifting gear
certificates, wire rope certificate and hook block certificate

Banks Man
Shall co-ordinate the lifting movements and maintains radio- and/or visual communication with crane
operator and persons close to the load.
shall participate in JHA/risk assessment/ toolbox talk for the lift.
Shall not get involved as Rigger when also performing the role of a Banksman.

Slinger /Rigger
To inspect the rigging, select rigging to suit the load, install the equipment.
To participate in JHA/risk assessment/toolbox talk for the lift.
To connect/disconnect the load.

5.0 Lift Planning and Execution

5.1 Defining the lift

Evomec ensures that when a lifting operation is to be carried out, it has to be checked if this
particular lifting operation has been carried out before on that site. A risk assessment and Lift Plan
might already exist.
If a risk assessment and Lift Plan do exist then they shall be assessed to confirm that they are still
applicable (e.g. changes to personnel, equipment, site layout or work environment could all result in
the need for re-assessment of hazards). Assuming that significant changes have not taken place
then lifting operations may proceed under the requirements of the Lift Plan subject to approval by
the lifting engineer.
If the lifting operations have not been carried out before, a competent person will prepare a Lift
Plan.
To define the lift the following parameters are established:
 Load weight, shape, centre of gravity and availability of adequate lifting points
 Initial and final load positions and how it will get there
 The environment in which the Lifting Equipment will be used

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 5.2 Planning

Risk Assessment
For every lifting operation Evomec ensures adequate risk assessment and control measures.
As part of the Hazard Effect Management Process (HEMP), a risk assessment will be carried out
prior to any lifting operation to identify associated hazards, their severity and likelihood of
occurrence. The Group (YG) ‘Risk Assessment Matrix’ (RAM) for determining risk is shown in App.1
and is the basis of the risk assessment process, with the objective of ensuring that all tasks have
Low Risk through elimination or adequate control. All risk assessments are formally documented. A
sample form is attached under.
The risk assessment will address the following aspects and activities:
 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
 Suitability and condition of Lifting Equipment to be used
 Initial and final load positions and how it will get there
 Ground and underground considerations

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  Lifting over live equipment
 Number and duration of lift(s)
 Conflicting tasks in area
 Environmental conditions including weather and permissible limits
 Lighting in the pick-up and lay-down areas
 Proximity hazards, obstructions, path of load (e.g. potentially live electrical, hydraulic or
pneumatic lines, underground conduits, bridges and overhead structures)
 Working under suspended loads
 Access and emergency escape routes for the Lifting Appliance Operator and load handlers
(e.g. Banksman, Slinger)
 Experience, competence and training of personnel
 Number of personnel required for task
 Pre-Use Inspection of equipment by Operator
 Visibility of the load at all times by either the Lifting Appliance Operator
or the person guiding the load (Banksman). He must maintain communication
with the Operator at all times either via hand signals, radio or a relay Signal Banksman.

Categorising Lifting Operations

As an aid to identifying risks and suitable controls, lifting operations are categorised to reflect
increasing risk and increasing level of control required as per categorisation scheme as given
below:

Routine Lifts
This classification comprises:
 Routine crane operations
 Repetitive lifting operations using the same equipment (eg drilling activities), and
 Routine lifting operations with Loose Lifting Equipment

A generic risk assessment and Lift Plan may be used for Routine Lifts. However, classifying 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 Plans shall
always be reviewed during the Toolbox Talk for continued applicability.

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 The control requirements for each category of lift are as follows:

Category of Lift Documentation/Controls Competent Personnel

Routine Crane Operations Risk Assessment Crane Operator
when: (generic) Banksman and / or
Gross load is less than 5 tonnes, Lift Plan (generic) Slinger/ Rigger
or (initiated by executing Drilling Crew
 Gross load represents less than department and approved
50% of the load chart at working by PDO’s lifting engineer)
radius Job Hazard Analysis
Within the normal operating Work Permit
parameters of the crane Toolbox Talk
 Lifting over non-sensitive areas Safety checklist
Suitable environmental conditions 10 questions for a safe
Familiar, competent Crane lift
Operators
Load has known and evaluated
weight, shape and centre of gravity
Standard rigging arrangements
Repetitive functions with same
equipment and with same operators
(eg repeat rig moves)

Non-Routine Lifts
Non-routine lifting operations can be further sub-divided to reflect increasing risk:
 Simple lifting operations using Loose Lifting Equipment
 Complicated lifting operations eg tandem lifting
 Complex / Critical / Heavy lifting operations requiring a Lift Plan with engineering input

The control requirements for each category of lift are as follows:

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Category of Lift Documentation/Controls Competent Personnel
Non-Routine – Simple Risk assessment Maintenance
when: Lift Plan initiated by Technicians
Gross load is less than 25 tonnes, executing department/ Riggers
or prepared by contractor
 Gross load is greater than 50%, but (approved by PDO’s lifting
less than 75% of the load chart at engineer)
working radius Job Hazard Analysis
Equipment specifically installed by Work Permit
a competent operator Safety checklist
Load has known and evaluated Toolbox Talk
weight 10 questions for a
Centre of gravity below the lifting safe lift
point
Use of a certified lifting point
directly above the load
Ample headroom
Outwith sensitive, difficult or
restricted areas
Single lifting appliance
Unlikely to be affected by changing
environmental conditions
Experienced and competent Lifting
Appliance Operator
Standard rigging arrangements
Suitable laydown area available

Non-Routine – Complicated Risk assessment Crane Operator

when:
Gross load is greater than 25
tonnes, or
 Gross load represents more than
75% of the load chart at working
radius, or
Gross load is greater than 30
tonnes and is also greater than 80%
of the manufacturer’s load chart
Specific Lift Plan Banksman (Signaller)
initiated by executing Slinger / Rigger
department/prepared by
contractor (approved by
PDO’s lifting engineer)
Job Safety Analysis
Work Permit
Safety checklist
Toolbox Talk

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Continuation of a lifting operation 10 questions for a
with different equipment (due to safe lift
malfunction, inadequacy or
unsuitability)
Use of two or more Lifting
Appliances (tandem lifting)
Within sensitive, difficult or
restricted areas

Non-Routine – Complex / Critical / Formal work pack with Crane Operator

Heavy Lift method statement, Banksman (Signaller)
when: including calculations Slinger/Rigger
Gross load is greater than 75 Lift Plan prepared and
tonnes, or reviewed by a qualified
 Gross load represents more than engineer (approved by
90% of the load chart at working PDO’s lifting engineer)
radius, or Risk assessment
 Gross load is greater than 50 Job Hazard Analysis
tonnes and is also greater than 80% Work Permit
of the load chart. Safety checklist
Continuation of a lifting operation Toolbox Talk
with different personnel; for example, 10 questions for a safe
shift changeover lift
Lifting of personnel, including drill
floor Man Riding operations
Over or in sensitive areas – active
or energized hydrocarbon-containing
process equipment, near overhead
electrical power lines
Use of two or more cranes
(tandem lifting)
Lifting with a helicopter
Transferring the load from one
lifting appliance to another (tailing lift)
In environmental conditions likely
to affect
equipment performance
Load with unknown / difficult to

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estimate weight and / or centre of
gravity
Load is special and / or expensive
whose loss would have a serious
impact on production operations
Non-standard rigging
arrangements
Load lowered into or lifted from a
confined space

Lift Plan
A Lift Plan is prepared or identified for every lift. The Lift Plan comprises of:
 The competent person planning the lift
 Calculations
 Equipment required
 Personnel required and their particular roles
 Step-by-step instructions
 Communication methods to be used
 Contingency and rescue plans

All Lift Plans – generic, specific or engineered – are developed, reviewed and approved by persons
competent to do so. This shall be initiated by the executing department.
A sample Lift Plan is included in App.2 showing the elements required.

5.3 Execution

Communication of Lift Plan

Prior to starting of lifting operations a competent person/ Safety Personnel shall hold a Toolbox Talk
with all personnel assigned to carry out the lift. Application of the ‘10 questions for a safe lift’ to the
lift shall be covered during the Toolbox Talk (Appendix 5).
The Person-in-Charge (PIC) shall be clearly identified and made known to all members of the lift
team and personnel in the proximity.
All personnel involved in the lifting operation shall have their individual responsibilities clearly
allocated.
All personnel shall have the opportunity to review the findings of the risk assessment and the details
of the Lift Plan to ensure that everyone clearly understands and agrees with the methods and
control measures to be used.

Conducting the Lifting Operation

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 Lifting operations shall be conducted in strict accordance with the approved Lift Plan. Any variation
from the agreed Lift Plan shall result in the job being stopped and reassessed to ensure continued
safe operation.
The Lifting Appliance Operator shall obey an emergency stop signal at all times, no matter who
gives it.
When lifting operations need to be controlled by signals, a designated signal person shall be
assigned. Signals between the Lifting Appliance Operator and the designated signal person
(Banksman / Signaller) shall be audible or visible at all times.
The appropriate load-radius chart for the Lifting Appliance configuration in use shall be visible to the
operator.
Load to be lifted shall be confirmed to be within the rated capacity of the Lifting Equipment and
attached by means of suitable Lifting Accessories.
The Operator of the Lifting Appliance shall not leave the operating controls while the load is
suspended.

Moving the Load

 Prior to lifting the PIC shall be satisfied that the load is secure and properly balanced and
that the load path is clear of obstructions and personnel
 At commencement of the first lift the Lifting Appliance Operator shall carefully check the
operation of the hoist brake to ensure no slippage occurs
 Take up sling slack to confirm that the Lifting Appliance hook has been positioned centrally
over the load lifting point, adjust the Lifting Equipment as necessary to minimise any ‘drift’ of
the load as it is lifted
 No external forces shall be applied to the load that create significant side loading of the
Lifting Equipment
 For crane operations appropriate tag lines shall be used to control the load– large or long
loads with flat sides that could act as a ‘sail’ are particularly prone to spinning and tag lines
shall be used – tag lines shall be secured to the load and not to the rigging slings
 Cranes shall not be used for dragging a load
 No fewer than five (5) full wraps of rope must remain on the winch drum in any operating
conditions.

Additional requirements, specific to particular equipment or operations, are detailed in App.3.

5.4 Reacting to changing conditions

All critical lifting parameters (e.g. weather, sea state, visibility, terrain stability and slope,
surrounding operations and installations, site access and egress, Lifting Equipment, personnel)
shall be identified during the risk assessment and preparation of the Lift Plan.
The PIC shall ensure that these conditions are monitored as lifting operations proceed to ensure
continued safety.
If, as part of the operation and maintenance of equipment, the computer system shuts down the
operation, the load must be placed on the ground and a new lift plan must be developed, eliminating
the condition that caused the shutdown.

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5.5 Procedures for recovering and landing the load in the event of the lift being aborted shall be clearly
identified. Learn and Record
After completing the lifting operation, everyone involved in the lift should have the opportunity to
discuss and make improvements to the Lift Plan. Any learning points noted on the plan must be
reviewed by a competent person and, where appropriate, action taken. Learning points may include
feedback on equipment effectiveness, lifting techniques, personnel, etc.

5.6 Application & Step-out and Approval

This Lift planning procedure is applicable to all lifting operations / lifting equipment in Evomec. As
such, this document is mandatory and shall be adhered to by all parties, involved in lifting
operations

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Appendixes
Appendix 1, Risk Matrix
The RAM provides one means of determining the level of risk associated with any task
through consideration of the potential severity of any incident and the likelihood of such an
incident occurring.

For different applications different overlays of the Risk Assessment Matrix can be used.
Consequences Increasing likelihood

A B C D E
Severity

Never Heard Incident Happens Happens

Reputation
Environment
People

Assets

heard of of in has several several

in Evome occurred times per times per
Evomec c in year in year in a
operatio operati Evomec Evomec location
ns ons Operatio
n
0 No No No No impact
injury damage effect
or
health
effect
1 Slight Slight Slight Slight
injury damage effect impact
or
health
effect
2 Minor Minor Minor Limited
injury damage effect impact
or
health
effect
3 Major Localise Localis Considera
injury d ed ble impact
or damage effect
health
effect
4 PTD* Major Major National
or 1 damage effect impact
fatality
5 Multiple Extensi Massiv Internation
fatalitie ve e effect al impact
s damage
*PTD = Permanent Total Disability

5.7 Step-out and Approval

Any step-out from this procedure shall be addressed to the lifting equipment engineer in writing. He will
review and authorise the deviation in exceptional circumstances.

Risk Assessment
…A scale of consequences from “0” to “5” shall be used to indicate increasing severity…
The potential consequences, rather than the actual ones, are used….

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…After assessing the potential outcome, the likelihood on the horizontal axis is estimated on the
basis of historical evidence or experience that such consequences have materialised within the
industry, the company or a smaller unit. Note that this should not be confused with the likelihood
that the hazard is released: it is the likelihood of the estimated consequences occurring.

…In Operating Units or new ventures where experience is limited, it is recommended that the
probability be assessed on the basis of knowledge from similar operations in other Operating
Units….

The following interpretations may assist in determining likelihood when assessing risks
specific to lifting and hoisting operations:

Low Risk May be acceptable but review task to see if risk can be reduced further.

Medium Risk Task should only be undertaken with appropriate management

authorisation after consultation with specialist personnel and assessment team.
Where possible, the task should be redefined to take account of the hazards
involved or the risk should be reduced further prior to task commencement.

High Risk Task shall not proceed. It should be redefined or further control measures put in
place to reduce risk. The controls should be reassessed for adequacy prior to task
commencement.

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Appendix 2, Sample Lift Plan
LIFTING OPERATION PLAN PAGE 1 of

Location: Area:

Permit Number: Risk Assessment Number:

Generic Lifting Plan No: Method Statement Number:

Is Diagram/Sketch/Calculations Of Lifting Operation Enclosed? YES/NO

nr.:
Description Of Lifting Operation:

Lift Category: Routine: Non-Routine:

Weight Of Load: Actual / Assessed
(delete as appropriate)
Lifting Equipment & Accessories to be used (specify type ,SWL and colour code)

All Lifting Operations Require The Following To Be Considered But This List Is Not Exhaustive.

Cultural, communication and language Conflicting tasks in area

difficulties
 Environmental conditions including
Weight, size, shape and centre of gravity weather and
of load  permissible limits
Lighting in the pick-up and lay-down
Availability of approved lifting points on areas;
load
Proximity hazards, obstructions, path of
load
Method of slinging/attaching/detaching the
load Working under suspended loads
Access and emergency escape routes
Overturning/load integrity/need for tag
lines Experience, competence and training of
personnel
Suitability and condition of lifting
equipment to be used Number of personnel required for task
Initial and final load positions and how it Pre-Use Inspection of equipment by
will get there operator
Visibility of the load
Ground and underground considerations

Lifting over live equipment

Number and duration of lift(s) 


Task Details (Step By Step)

Method(s) Of Communication To Be Used Radio Verbal Hand

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Signals 
Steps Taken To Eliminate Danger To Personnel Involved and Others (including barriers where
appropriate):

De-brief and learning points:

Prepared By/Name: Signature:

Date:

Reviewed By/Name: Signature:

Date:

Approved By/Name: Signature:

Date:

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 Appendix 3, Site Plan Warri Stacking Area

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