PLANNING LIFTING & HOISTING OPERATIONS Page 1 of 20

DOCUMENT NUMBER: PERMIT TO WORK REFERENCE:

LOCATION: Shell Pasir Gudang MAX WIND SPEED: 15m/s - 20 m/s

AREA: Product Pump Shed MAX SEA STATE: N/A

BRIEF DESCRIPTION OF LIFTING & HOISTING OPERATION

Lifting activity for U97 VPR pump Pipe line replacement using 25 Tones Mobile cranes at the Terminal Product pump shed.
Work execution will divide by demolition of existing pipe line and installation of new pipe spool after the existing pipe line has
been remove.
Lifting activity consist of straight pipe spool and pipe spool with flanges branch.
CATEGORISATION OF LIFTING AND HOISTING OPERATION (UNDERLINED: HSSE CF CATEGORIES; free format in “Other”)

Routine Non-Routine Simple Non-Routine Complex Other:

Generic Risk Assessment:

Procedure reference: Lift Plan Drawing number: Specific Risk Assessment:
MS-M2016-CON-JHA-
Refer below Refer below
004

PIC: Crane Operator/s: Signalman/men: Riggers:

Zakri Firdaus Jean Muhammad Firdaus Mohd Ali Azhar Hardam

BRIEF DESCRIPTION OF THE LIFTING & HOISTING EQUIPMENT TO BE USED

(E.G. TYPE, WLL, SWL, ETC and including rigging weight total)

Mobile Crane Kato SR-250R with Maximum Lifting Capacity at Radius of 18m = 2.7mt.
CURRENT
Webbing Sling with SWL of 3mt x 6m L (2nos)
COLOUR N/A
Shackle with SWL of 4.75mt
CODE
(Please refer the Crane Load Chart and certificate for the lifting accessories)

BRIEF INFORMATION OF THE LOAD(S) (including base weight/s):

Load with max gross weight of pipe spool 300kg rigged using 2 nos x 3t x 6m certified webbing sling and 2 nos x 4.75t certified
shackle. Lifting using chocker hitch method. Tabulation weights refer sequence table (Page 7 for demolition and Page 9 for New
pipe installation).
LOAD WEIGHT CALCULATION
(Including weight contingency + any other factors such as DAF) Note: Utilization > 75% = Non-Routine, Complex

Calculation A

The heaviest straight spool pipe for demolition and new pipe spool installation
Load Weight.

1)Pipe 8”, ASTM A106 GR B, Sch 20 2) Flange 8” ASTM A105, Sch 40

Linear weight: 33.31 kg/m Weight per unit: 17.6kg
Quantity: 2 pcs
Horizontal spool Total: 36kg
Quantity: 1pcs MAXIMUM
Length: 6.92m UTILIZATION 15.7 %
W: 6.92m x 33.31kg/m = 231kg TOTAL: 267kg %

Rigging Gear Weight

Webbing Sling with SWL of 3mt x 6m L (2nos) = 5.4 kg
Shackle with SWL of 4mt (2nos) = 2.4 kg
Hook Blook with SWL of 25mt = 60 kg

TOTAL: 67.8kg

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Load weight + Ringing weight
= 267kg + 67.8kg
= 334.8kg

Total Weight + Contingency + DAF

334.8 x 1.10 x 1.15 = 423.5 kg

Crane Lifting Capacity at Radius of 18.0 meters

2,7 00 kg

Maximum Utilization
(0.424 / 2.7) x 100 = 15.7%

Safety factor
= 2.7 / 0.424) x 100
= 6.3
………………………………………………………………………………………………………………………………………………………….
MAXIMUM
Calculation B UTILIZATION 12.7%
%
Heaviest Spool Pipe with Branch for Pipe Demolition and New Pipe spool Installation load
weight.

Load Weight
1)Pipe 8”, ASTM A106 GR B, Sch 20 2) WN Flange 8” ASTM A105, Sch 40
Linear weight: 33.31 kg/m Weight per unit: 17.6kg
Quantity: 3 pcs
Total: 52.8kg
3) Blind Flange SA 105 CL150 Sch 20 4) Pipe 2” SA106 sch40
Weight per unit: 19.6kg Linear Weight: 5.44 kg/m
Quantity: 1 pcs
Total: 19.6kg

5) Pipe 3” SA106 sch 40 6) WN Flange 2” A105 sch 40

Linear Weight: 11.29 kg/m Weight per unit: 2.58kg
Quantity: 1 pcs
Total: 2.58kg
7) WN Flange 3” A105 sch 40 8) Straight TEE 8” SA 234 GR
Weight per unit: 5.21kg Weight per unit: 17kg
Quantity: 1 pcs Quantity: 1 pcs
Total: 5.21kg Total: 17kg

9) Elbow 8” sch 20
Weight per unit: 13.5kg
Quantity: 1pcs
Total: 13.5kg
Horizontal spool
Quantity: 1pcs
Length: 2.4m
W: 2.4m x 33.31kg/m = 80kg

Vertical
Quantity: 3pcs
Pipe 2” Pipe 3”
Length: 0.146m Length: 0.14m
W: 0.146m x 5.44kg/m = 0.8kg W: 0.14m x 11.29kg/m = 1.58kg

Pipe 8”
Length: 0.34m
W: 0.34m x 33.31kg/m = 11.3kg

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TOTAL : 204.37kg

Rigging Gear Weight

Webbing Sling with SWL of 3mt x 6m L (2nos) = 5.4 kg
Shackle with SWL of 4mt (2nos) = 2.4 kg
Hook Blook with SWL of 25mt = 60 kg

TOTAL: 67.8kg

Load weight + Ringing weight

= 204.37kg + 67.8kg
= 272.17kg

Total Weight + Contingency + DAF

272.17x 1.10 x 1.15 = 344.3 kg

Crane Lifting Capacity at Radius of 18.0 meters

2,7 00 kg

Maximum Utilization
(0.344 / 2.7) x 100 = 12.7%

Safety factor
= 2.7 / 0.344) x 100
= 7.8

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ALL L&H OPERATIONS REQUIRE THE FOLLOWING - AS A MINIMUM - TO BE CONSIDERED

THIS INFORMATION IS TO BE CAPTURED IN A SEPARATE DOCUMENT (E.G. METHOD STATEMENT/RA)
15. Hoisting over live equipment
16. Conflicting tasks in area
1. Relevant Life Saving Rules
17. Working under suspended loads
2. 10 Questions for safe Lifting & Hoisting
18. Overturning, load integrity, need for tag lines
3. Toolbox or Pre-Job meeting
19. Environmental conditions incl. weather, sea state
4. Weight, size, shape and centre of gravity load
20. Experience, competence & training of personnel
5. Method of slinging, attaching, detaching the load
21. Number & names of personnel required for task
6. Availability of approved hoisting points on the load
22. Communication requirements
7. Manufacturer equip use information to be followed
23. Lighting in the pick-up and lay down area
8. Manufacturer load lifting information to be applied
24. Initial and final load positions & how it gets there
9. Maximum radius of hoisting the load
25. Proximity hazards, obstructions, path of load
10. Verified details of ground conditions/capacity
26. Suitability and condition of equipment
11. Area for setting up with outriggers fully extended
27. Pre-use inspection of certified equipment only
12. Access and emergency escape routes
28. Max dynamic calculated load is within capacity
13. Number and duration of lifts, hoists
14. Visibility of load (blind lifts = Non-Routine Complex)

METHOD (S) OF COMMUNICATION TO BE USED:

Radio: Yes Verbal: Yes / Whistle Hand Signals: Yes

PRE-TASK PREPARATION (as a minimum – not exhaustive)

1. Lift plan reviewed and signed.

2. All personnel associated with the lifting operation to review the lifting plan and risk assessment and complete toolbox talk
at job site immediately prior to starting to lift each shift
3. Crane operator to inspect the load/s and ensure the actual weight/s of the cargo measured by the crane matches those
stated in the lifting plan, and when initially lifting loads, that the crane LMI indicates no more than the expected load
4. Crane operator and LS to inspect work area and ensure ground load bearing surface is safe/adequate for maximum loads
imposed by this operation, crane must be level within 1 degree and all wheels clear of ground
5. Crane operator to carry out pre-check/inspection of the crane and test all safety devices are functioning correctly
6. LS to ascertain that the environmental conditions are within crane parameters and those as stated in Lifting Plan
7. LS to ensure area barricaded, no conflicting activities ongoing in surrounded/landing areas and load path is clear of
obstructions, including no personnel standing on crane or within swing range of crane
8. LS to ensure suitable access for Rigger/s to safely attach/adjust rigging at height, and load is free to lift
9. LS to inspect all rigging and equipment prior to use, and confirm colour code is valid
10. Area Authority to open PTW only if all above conditions have been met as a minimum
11. Commence operation step by step plan as per drawings (next page)

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TASK STEP BY STEP – ATTACH ADDITIONAL PAGES IF REQUIRED

Lifting to Remove Existing Pipe Spool

1. Conduct TBT and ensure all workers are aware of tasks, hazards and risk during the activity. The whole lifting operation is
led by the Lifting Supervisor (LS) and assisted by Rigger.
2. LS to confirm all steps from Pre-Task Preparation and complete the whole lifting activity is controlled.
3. Barriers confining the lifting area shall be in place to avoid unauthorised entry.
4. Proper signage shall be displayed at the lifting area.
5. LS to ensure the lifting location is clear from any obstruction.
6. LS to ensure 1 Rigger at lifting location.
7. LS to ensure the rigging is free to lift and hanging over top of the load.
8. LS to direct Crane Operator to position crane hook above the load.
9. LS directs Rigger to attach webbing sling to pipe at specific points referring to the Lifting Plan.
10. LS directs Rigger to attach webbing sling to crane block hook, ensuring safety catch is closed.
11. LS direct Rigger to attach tag-lines for load movement control to avoid any free movement.
12. Once the load ready to be lifted, the LS to ensure all personnel clear out of load and directs Crane Operator to pick the load
to a safe height.
13. Once load is confirmed stable, LS directs Crane Operator to move the load to its desired location.
14. Once the load is position to the designated location, LS directs Rigger to approach load and disconnect crane hook.
15. Once Riggers clear of load, LS directs Crane Operator to raise crane block and move to a safe location
16. LS instructs Rigger to remove tag-lines and ensure load is secured and correctly positioned.

Crane arrangement and pipe spool arrangement on site.

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Crane Location In front of Pump Shed

Area for Heavy Duty Scaffolding Live Asset Protection.

Heavy Duty
Scaffolding Protection
Structure

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Existing Pipe Line Cut into Spool Prior To Lift and Remove from Site.

SP-01

SP-06 SP-05

SP-04

SP-03

SP-02

Sequence for Lifting Demolition Pipe with weight tabulation

NO PIPE SPOOL NO LOAD (kg)

1 SP-01 140

2 SP-02 128.6

3 SP-03 83.27

4 SP-04 83.27

5 SP-05 103.2

6 SP-06 70.32

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Lifting New Pipe Spool

1. Conduct TBT and ensure all workers are aware of tasks, hazards and risk during the activity. The whole lifting operation is
led by the Lifting Supervisor (LS) and assisted by Rigger.
2. LS to confirm all steps from Pre-Task Preparation and complete the whole lifting activity is controlled.
3. Barriers confining the lifting area shall be in place to avoid unauthorised entry.
4. Proper signage shall be displayed at the lifting area.
5. LS to ensure the lifting location is clear from any obstruction.
6. LS to ensure 1 Rigger at lifting location.
7. LS to ensure the rigging is free to lift and hanging over top of the load.
8. LS to direct Crane Operator to position crane hook above the load.
9. LS directs Rigger to attach webbing sling to pipe at specific points referring to the Lifting Plan.
10. LS directs Rigger to attach webbing sling to crane block hook, ensuring safety catch is closed.
11. LS direct Rigger to attach tag-lines for load movement control to avoid any free movement.
12. Once the load ready to be lifted, the LS to ensure all personnel clear out of load and directs Crane Operator to pick the load
to a safe height.
13. Once load is confirmed stable, LS directs Crane Operator to move the load to its desired location.
14. Once the load is position to the designated location, LS directs Rigger to approach load and disconnect crane hook.
15. Once Riggers clear of load, LS directs Crane Operator to raise crane block and move to a safe location
16. LS instructs Rigger to remove tag-lines and ensure load is secured and correctly positioned.

Crane location to Lifting New Pipe Spool

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Sequence for Lifting New Pipe Spool Installation with weight tabulation

NO PIPE SPOOL NO LOAD (kg)

1 SP-01 (DW-001) 267

2 SP-02 (DW-001) 178.6

3 SP-03 (DW-001) 165.1

4 SP-01 (DW-002) 210.17

5 SP-02 (DW-002) 175.1

6 SP-03 (DW-002) 68

LIFT PLAN DRAWING

(incl. load path & rigging arrangement) – ATTACH ADDITIONAL PAGES IF REQUIRED

Refer to the attached Lifting Plan –

WEBBING SLING UTILIZATION

Refer to the attached Lifting Plan –

CRANE LIFTING CAPACITY

Refer to the attached Crane Load Chart – KATO SR-250R LOAD CHART

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Lifting Activity Location

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Lifting Arrangement remove existing pipe

Pipe Location to
remove

PUMP SHED

6000
Out rigger Plate

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Crane Working Range

26000

18000

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Crane Working Range

RIGGING ARRAGEMENT FOR STRAIGHT PIPE SPOOL

Sling
3T x 6M
5732
6000

Single
Chocker
COG

1500 1500

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RIGGING ARRAGEMENT FOR BRANCH PIPE SPOOL

Sling
3T x 6m
5732
6000

Single
Chocker

COG

1000 1000

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LIFTING ARRANGEMENT FOR INSTALL NEW PIPE SPOOL

New Pipe Spool
Location

PUMP SHED

6000
Temporary
Storage

Out rigger Plate

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DOCUMENT NUMBER: PERMIT TO WORK REFERENCE:

LOCATION: Shell Pasir Gudang MAX WIND SPEED: 15m/s - 20 m/s

AREA: PUMP Shed MAX SEA STATE: N/A

Learning From L&H Activity

Sling Tension at Angle Sling Capacity loss at Angle

LEG ANGLE (°) FACTOR LEG ANGLE (°) FACTOR

90 1.000 90 1.000
85 1.003 85 1.003
80 1.015 80 1.015
75 1.035 75 1.035
70 1.064 70 1.064
65 1.103 65 1.103
60 1.154 60 1.154

Load weight Hitch Method

= 0.5Ton Chocker

Leg from COG Hitch factor

= 1500mm = 0.8

Length between Leg Sling capacity

= 3000mm = 3 Ton

Load Weight at Leg Sling Capacity by Hitch method

=(1500/3000) x 0.5 = 3 x 0.8
= 0.25Ton = 2.4 Ton

Leg angle Leg Angle

= 60.0° = 60.0°

Load Weight at Angle Sling Capacity at Angle

= 0.25T x 1.154 = 2.4 Ton x 0.8660
= 0.29 Ton = 2.07 Ton

Sling Capacity Utilization

= (0.29 /2.07) x 100%

= 14%

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Crane Specification

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Crane Specification

25.5

17.5

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Lifting Supervisor

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Rigger and Signalman

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