S Y S T E M

QHSE MANAGEMENT SYSTEM PROCEDURE FOR

SAFE LIFTING OPERATION

Revision : 00
M A N A G E M E N T

Issue Date : May 2017

Review Date : June.2018

Q H S E
 DOCCUMENT CHANGE RECORD

REV. DATE OF PAGES BRIEF DESCRIPTION OF CHANGES

# REV.
 TABLE OF CONTENTS

S.# CONTENTS PAGE #

0. Distribution List 3

0. Terms & Definitions 3

0. List of Abbreviations 5

1. Purpose 6

2. Scope 6

3. Responsibilities 6

4. Procedure 6

4.1 Components of Safe Load Lifting Job 6

4.2 Responsibilities 7

4.3 Preventive Maintenance, Inspection, and Certification 9

4.4 Records of Inspections, Tests and Certification 10

4.5 Lifting Gears 10

4.6 Inspection / Testing of Lifting Gear 11

4.7 Manpower Certification 11

4.8 Requirements for Lifting Appliances 12

4.9 Requirements for Lifting Gears 18

4.10 Inspection Frequency & Color Coding 21

5. Training & Evaluation 26

6. Related Documents & Records 26

 DISTRIBUTION LIST
This manual is available on IS portal and accessible to all employees of ABC.
TERMS & DEFINATIONS

Rigging Supervisor, Safety Watch, Crane Operators, and Signalman/Banks

Certified Rigging
man who have undergone training and subsequent certification by a ISE-
Personnel
approved Third-Party Inspection Authority.

Company A person who, by virtue of appointment, has authority to represent ISE in all
Representative matters with the Contractor concerning performance of work, provision of
services, or supply of goods.

Crane Safety Watch A Company employee or contractor who has undergone training and subsequent
certification by a Company-approved Third-Party Inspection Authority and is
responsible for safe load lifting operation of a crane. His presence is mandatory
for all "Critical Lifts."

Critical Lift Any load-lifting job that is out of the ordinary or may approach the limitations of
the lifting equipment or skill level of the operators. Critical lifts include, but not
limited to, Heavy Lifts (80% of crane capacity), High-wind Exposure Lift, High
Cargo Cost Lift, High Risk (Fire or Explosion) Lift, Fragile Cargo Lift, Hazardous
Environment / Visibility Lift, and Danger Zone Lifts liable to cause partial or total
shutdown of the plant.

Danger Zone of Lifting The area around lifting equipment that may be affected in case of lift failure.
Equipment Arithmetically it is estimated as horizontal radius of lift plus the largest dimension
of load that is to be lifting.
(Danger Zone = Radius of lift + Largest of the load dimensions)

Equipment Checklist List identifying attributes required to be checked and approved prior to equipment
entry into Company work sites.

Facility Any location including Construction, Drilling, Maintenance, Productions,

Warehouse, and Camps within Company area of operations where work is being
carried out for and on behalf of the Company.

Facility-in-Charge / Company's senior-most supervisor who is present at the location and is

Location Supervisor responsible for carrying out operations within the facility area.

Lifting Equipment A Company employee or contractor who has undergone training and subsequent
Operator certification by a Company-approved Third-Party Inspection Authority and is
designated to operate crane, forklift, etc. The operator should have appropriate
experience and training (classroom and hands-on), and has also met the
requirements of a qualified rigger.

Lifting Gear Equipment and equipment parts used in fastening or securing loads for
mechanical lifting such as a chain, sling, rope sling, ring, link, hook, plate clamp,
shackle, swivel, eyebolt, or similar gear.
Load Test Method of verifying the capacity of a lifting equipment by lifting a "dummy" load
of known weight at a measured radius, and then performing different maneuvers,
i.e., hoisting, lowering, slewing (swinging) at 180 degrees, and finally lowering
the load from about five feet height at full speed and suddenly stopping when
load is one foot above ground. Dummy load should be 10-25% above the
equipment's rated capacity or according to manufacturer's recommendations.
The test is done in the presence of a Company representative.

Rigging Supervisor A Company employee or Contractor who has undergone training by a Company-
approved Third-Party Inspection Authority and has a minimum of five years’
experience in supervising lifting operations. His presence is mandatory for all
Critical Lifts.

Safe Working Load (SWL) The relevant safe working load required to be specified in records of test and
examinations, and to be marked on the lifting equipment and the lifting gear.

Signalman / Banksman A person who has undergone training and subsequent certification by a
Company-approved Third-Party Inspection Authority for signaling the Lifting
Equipment Operator during a lifting job.

Tandem / Multiple Lift Lifting operations involving use of more than one crane. Cranes used should
have equal lifting capacities.

Risk Assessment (RA) Tool used for listing distinct activities within a job identifying various associated
risks, categorizing these risks on severity, and chalking-up a safety plan to
remove/control such risks. Technique is mainly used for non-routine / critical lift
jobs.

Third-Party Inspection An internationally recognized crane and lifting equipment inspection agency
Authority approved by ISE.

Work Permit A document issued by a Permit Issuing Authority allowing the performance of
specific tasks in a specified location for a specified duration, identifying
associated hazards and control measures required.

LIST OF ABBREVIATIONS
CSR Company Site Representative
DIC Drilling Incharge
HO Head Office
W/O Work Over
1.0 PURPOSE:

The purpose of this procedure is to ensure safe working conditions and practices during lifting
operations carried out within Company work sites, either by Company or Contractor employees.

2.0 SCOPE:

All drilling and Work over sites of Drilling and Well Engineering Department.

3.0 RESPONSIBILITY & AUTHORITY:

Primary responsibility pertaining compliance of below mentioned QHSE requirements rests with
Company Site Representative and Well Site HSE Officer.

4.0 PROCEDURE:

4.1 Components of Safe Load Lifting Job

Following activities shall be ensured to achieve safe load lifting jobs.
4.1.1 Every employee is authorized to stop any unsafe rigging operation.
4.1.2 It will be ensured that lifting equipment, hoists, and all lifting gear are fit for use and their
certification by a ISE approved Third-Party Inspection Authority valid.
4.1.3 Inspection of Company and contractor cranes and associated rigging equipment will be carried out
in accordance with the Standing Instructions.
4.1.4 It will be ensured that Task Risk Assessment (TRA) is reviewed and approved prior to commencing
non-routine/critical-lift jobs. If a lift is classified as critical, then additional precautions should be
taken (load tests, consultations, additional safety reviews, dry runs, etc.) to increase the assurance
that the lift will be completed in the safest possible manner.
4.1.5 A current list of certified crane operators and riggers will be maintained on all ISE operated facilities
and rigs on the database by Contract Sponsor/Purchasing Department.
4.1.6 It will be ensured that personnel involved in the rigging operation (ISE /Contractor Supervisors,
Operators, Signalman, and Safety Watchman) are all certified and that their on-the-job
performance is observed and examined.
4.1.7 Crane load limits are adhered to at all times. The crane operator will know the weight of the load
and assure that it is within acceptable limits on the load chart before lifting.

4.1.8 Crane load-radius charts for static and dynamic lifting will be located in plain sight of the operator
and used for each lift.
4.1.9 Riggers and signalmen will be competent in the use of appropriate hand signals.
4.1.10 It will be ensured that no lifting job commences without Rigging Work Permit being issued first, as
per the Permit to Work procedure.
4.1.11 Personnel will avoid being under any part of the crane boom or load.
4.1.12 A Preventive Maintenance (PM) program is required for all cranes (see Section 7.0).
4.1.13 Lifting equipment that satisfies the checklists shall be deployed within ISE work areas/facilities.
This equipment in turn shall be operated/handled by authorized personnel under PPL certified
supervisors and after obtaining appropriate work permits.
4.1.14 It will be ensured that ground conditions are suitable enough to bear the total weight (the load being
lifted plus the weight of lifting equipment). Therefore, ground condition must be checked/tested and
extra sleepers/plates placed underneath outrigger plates for critical lifts. Ensure that wooden
sleepers or steel plates are always kept with crane for this purpose.
4.1.15 A well-engineered written lifting-plan, where one person is in-charge and every crewmember has
been briefed about his tasks, exists. A lifting plan should elaborate step by step activities in order
of their occurrence along with calculations and should contain following as minimum information:
4.1.15.1 Weight of the load to be lifted with its dimensions and probable centre of gravity.
4.1.15.2 Weight of lifting slings, hooks, and spreader bars, pulleys, etc.
4.1.15.3 Details of duty chart of lifting equipment and an attested copy of the chart in case it is not
available in operator’s cabin.
4.1.15.4 Dimensions of crane/lifting equipment along with sketches showing slinging points on
load, various positions and angles of boom, lifting capacities at those radii and clearances of slings
/ Hooks /pulleys.
4.1.15.5 It is recommended that all the dimensions be drawn to scale including equipment, load
sizes, and site clearances. Side and plane views are a must for tandem lift (when two cranes are
used simultaneously to lift a load) along with tailing arrangement.
4.1.15.6 Safety aspects including safe removal of slings are mentioned in it.
4.2 Responsibilities
Following personnel are responsible for ensuring compliance with this procedure, and with applicable
regulatory requirements relating to mechanical lifting operations:
4.2.1 Location Supervisors
Location Supervisors shall include Facility In-charge, Project Managers, Construction Managers,
Construction Superintendent, Warehouse/Purchasing Manager, Production Superintendent, Field
Operation Engineer, and Rig Move Coordinator. They shall ensure that:
4.2.1.1 A Rigging Supervisor is appointed to control the inventory of lifting equipment and arrange its
periodic examination/certification in accordance with applicable regulations and standards.
4.2.1.2 All supervisors involved in lifting operations understand the requirements of the procedure.
4.2.1.3 A system of review and control is established to ensure that standards are appropriate to the
requirements of the operation.
4.2.2 Rigging Supervisor
At all stages during the progress of a lifting operation, from planning through to completion, the Rigging
Supervisor shall ensure that all necessary precautions are in place to carry out the job in the safest possible
manner. His responsibilities include:

Lifting Equipment
4.2.2.1 Maintaining a current inventory of lifting equipment and gear including their conditions and
serviceability.
4.2.2.2 Ensuring lifting equipment and gear undergo periodic inspection and certification, and are
in good working condition. Load testing shall be performed where required.
Rigging Personnel
 4.2.2.3 Ensuring that all Rigging personnel are competent and properly trained, and Certified
Rigging Personnel are in possession of valid certificates.
Safe Lifting Operation
4.2.2.4 Determining, along with the Job-Site Representative, if a lift is critical or non-critical.

4.2.2.5 Ensuring that a Task Risk Assessment (TRA) is carried out, if required.
4.2.2.6 Making sure that rigging plan for a critical lift is available in writing at Site.
4.2.2.7 Obtaining the necessary Work Permit / Vehicle Entry Permit.
4.2.2.8 Ensuring that conditions are suitable for the operation (i.e., ground conditions, weather
conditions, and wind direction/speed).
4.2.2.9 Making sure that safety briefings and assigning of tasks/duties have been done prior to start
of a critical lift.
4.2.2.10 Ensuring that the load does not exceed the dynamic and/or static capacities of the lifting
equipment.
4.2.2.11 Ensuring that the load is known and its center of gravity is the lifting point, or the lifting
slings straddle this point.
4.2.2.12 Ensuring that load is free from any engagement or unknown force before lifting.
4.2.2.13 Ensuring that load is kept as close to the ground as possible.
4.2.2.14 Ensuring that no one is on the load or underneath the load.
4.2.2.15 Making sure that the danger zone is free from standby observers.
4.2.3 Crane Safety Watch
The Crane Safety Watch shall:
4.2.3.1 Visualize various positions of the load before actual lift.
4.2.3.2 Observe that the crane is leveled on a firm ground and it remains leveled during the entire lift.
4.2.3.3 Examine that two hold off wires/tag lines are tied up with the load and controlled by riggers.
4.2.3.4 Monitor that truck-mounted crane lifts over the back, never over the cab.
4.2.3.5 Examine that slings are not used at wide angles. Preferable angle of slings with respect to load is
90 degrees. It may not be always possible to sling a load at 90 degrees, so the angle may be less
than 90 degrees, but less than 60 degrees should be avoided.
4.2.3.6 Examine that all links, rings, shackles ride the hooks freely.
4.2.3.7 The load on the hook shall be applied only at the bottom of the circular part of the hook, whatever
type of hook is in use.
4.2.3.8 Ensure that when two eyes from spreader slings are required to be brought back on to one hook,
they shall be first brought into a shackle that in turn shall be hung freely from the hook.
4.2.3.9 Monitor that riggers are properly dressed - loose clothes and leather gloves are discouraged. Safety
shoes with rubber sole are preferred.
4.2.3.10 Examine that outriggers are set to the maximum possible width.
4.2.3.11 Examine that outriggers remain under watch throughout the job execution.
4.2.3.12 Slings are not run around sharp corners or shortened using knots or attached to a fitting that is
smaller than sling rope in diameter.
4.2.4 Lifting Equipment Operator

Lifting Equipment Operators include certified operators of Cranes, Gang Truck, and Forklift. He is
responsible for his lifting equipment and shall:
4.2.4.1 Check the condition of the lifting equipment before starting work.
4.2.4.2 Report to his supervisor any obvious defects or required repairs.
4.2.4.3 Never elevate a load with the lifting equipment on an incline, until machine is leveled.
4.2.4.4 Carry loads as close to the ground as possible.
4.2.4.5 Ensure that when reversing the vehicle, at least one person is signaling from the rear (at least two
persons when inside the plant).
4.2.4.6 Ensure that he does not rely on horn beep safety.
4.2.4.7 Ensure that starts and stops are done gradually and slowly.
4.2.4.8 Maintain a safe distance from other vehicles when travelling the lifting equipment.
4.2.4.9 Never overtake other vehicles while load is lifted.
4.2.4.10 Avoid stunt driving and horseplay while operating the lifting equipment.
4.2.4.11 Slow the vehicle down on wet and slippery surfaces.
4.2.4.12 Go slow and sound the horn at corners.
4.2.4.13 Avoid running over loose objects.
4.2.4.14 Always watch load and mast overhead clearance.
4.2.4.15 Keep hand and feet inside the lifting equipment.
4.2.4.16 Not allow the lifting equipment parts to strike other objects.
4.2.4.17 Observe ground condition and ground load limits.
4.2.4.18 Use an assistant when going up or down a ramp.
4.2.4.19 Not carry passengers on the lifting equipment.
4.2.4.20 Shut off his lifting equipment, lower the boom, and tie hook with machine body before leaving it
unattended.
4.2.4.21 Not smoke on the job.
4.2.4.22 Check the condition of his lifting equipment after a day's work.
4.3 Preventive Maintenance, Inspection, and Certification
A Preventive Maintenance (PM) Program shall be applied to all Company-owned lifting equipment in
accordance with the manufacturer's specifications and records kept in the Maintenance tracking system.
Maintenance program shall include not only mechanical components, but also all alarm/safety devices and
lifting accessories. In addition to the regular maintenance, all lifting equipment shall be inspected and
certified every year by a Company-approved Third-Party Inspection Authority. The examiner shall issue
certificates to equipment clearing inspection.
All lifting equipment should also have the required local government certificates, where applicable.
Rental equipment that stays with the Company will also follow a Preventive Maintenance Program covering
all mechanical and safety aspects. A PM program checklist, which is based on recommendations from
equipment's manufacturer, is to be pre-approved by Company representative. This checklist is to be
maintained by the Contractor and provided to the Company representative upon request prior to lifting
operation. In addition to the regular maintenance, all contractor-owned lifting equipment shall be inspected
and certified every year by a Company-approved Third-Party Inspection Authority. The examiner shall
issue certificates to equipment clearing inspection.
Once the lifting equipment and the associated lifting gear have been certified, the following shall apply:
4.3.1 Lifting equipment shall not be allowed to be used unless current records of tests and examinations
are made available to Company representative.

To be current, records must show that the lifting equipment has been tested and thoroughly
examined satisfactorily by a Company-approved Third-Party Inspection Authority within the
previous 12 months (or since the last substantial alteration or repair that could affect its stability).
Any lifting equipment that has been altered or repaired will have to be re-certified by the Company-
approved Third-Party Inspection Authority. To do this, Contractor shall provide a document stating
alterations/repairs carried out. These alterations/repairs can be due to contractor's own

Maintenance program or can also be in response to Company inspections and subsequent

remedial actions.
4.3.2 All wire ropes, chains, and slings shall be tested and certified by a Company-approved Third-Party
Inspection Authority before first use. Lifting Gear shall not be used unless there are current records
of tests and examinations. To be current, records must show that the Lifting Gear has been tested
and thoroughly examined satisfactorily by a Company-approved Third-Party Inspection Authority
within the previous 12 months (or since the last substantial alteration or repair that could affect its
stability). Any Lifting Gear that has been altered or repaired will have to be re-certified by the
Company-approved Third-Party Inspection Authority. To do this, Contractor shall provide a
document stating alterations/repairs carried out. These alterations/repairs can be due to
contractor's own maintenance program or can also be in response to Company inspections and
subsequent remedial actions. Additionally, all Lifting Gear shall be thoroughly examined every six
months and records maintained by the contractor. The Company reserves the right to request proof
of inspections at any stage of the work.
4.3.3 Any lifting equipment, accessory, sling, shackle, which has been tested and certified by a
Company-approved Third-party Inspection Authority shall only be visually inspected (per Rigging
Procedures in rigging books) before load lifting.
4.3.4 All hoists shall be tested and thoroughly examined before first use and after substantial alteration
or repair. These shall be thoroughly examined every six months.
4.3.5 All critical load-lifting jobs shall require physical load testing of the Lifting Equipment and the Lifting
Gear within 250-meter radius of the actual load-lifting spot.
4.3.6 Prior to its entry in a facility or rig site, it is mandatory that Lifting Equipment qualifies checklist.
4.3.7 It shall be verified that a Load Moment Indicator (LMI) or Load Moment Limiter (LML) is installed
and functional.
4.3.8 Outriggers will be checked for their functionality.
4.3.9 Adequate guarding of moving parts, including within the operator's cabin should be verified.
4.3.10 Safe access for the crane to the work site should be ensured.
4.4 Records of Inspections, Tests and Certification
The Contractor will provide records of all inspections, tests, and certifications performed in Section 4.3 to
the Company representative prior to lifting operation. Contractor supervisor (CS) shall maintain these
records so that a central database is available for immediate reference. CS will then ensure that this
information is disseminated and readily available at all Company work sites.
4.5 Lifting Gear
The following shall be ensured for all Lifting Gear:
4.5.1 All new Lifting Gear shall be certified by the manufacturer or the supplier and shall be supplied with
a certificate specifying identification number and safe workload.
4.5.2 Lifting Gear produced, modified, or repaired locally shall be designed and manufactured according
to applicable industry standards (ISO, ANSI, BSI, etc.) and shall be inspected, load-tested, and
 Certified by a Company-approved Third-Party Inspection Authority prior to use, and the inspection
documented.
4.5.3 The Safe Working Load (SWL) will be clearly indicated on all Lifting Gear. SWL can be marked on
the equipment, or on a tag fastened to the equipment.
4.5.4 Welding on any type of lifting equipment is not permitted.

4.5.5 Wire rope purchased for use in a crane winch shall be the same type and capacity as the wire rope
supplied by the crane manufacturer. The wire rope shall be purchased with certification from the
supplier. All certification documents shall be kept on file until the wire ropes are discarded.

4.5.6 Lift slings shall be purchased with the correct sockets. Never make lift slings from existing wire
rope in the field.
4.5.7 Plastic coating shall not be permitted on wire rope slings. Lubricant is the only coating permitted
on slings.
4.5.8 Only steel alloy type of chain is permitted in hoisting. The chain shall be identified by a letter code
on the chain links.
4.5.9 Pins, shackles, and clevises shall be of approved types and shall not be replaced with bolts. All
lifting accessories shall have a SWL rating that is more than the rating for the sling or chain.
4.6 Inspection / Testing of Lifting Gear
All winch cables and lift slings shall be inspected for the following before each use:
4.6.1 Six broken wires in one lay of length, or three broken wires in one strand in one lay of the length.
4.6.2 Two or more broken wires at the socket end of the cable.
4.6.3 Bends, twists or other damage affecting the shape of the rope or causing the twist of the rope to
become loose.
4.6.4 Indications of heat damage.
4.6.5 A large area of corrosion.
4.6.6 End attachments that are worn, cracked, or broken.
4.6.7 Cables and slings have a coating of lubricant to prevent corrosion and reduce friction. If the
lubrication that was applied at the factory has been removed, the cable/sling shall be cleaned and
a new coating applied during inspection.
4.6.8 Slings that become wet with salt water shall be washed with fresh water and dried prior to
lubrication.
4.6.9 Chains shall be inspected for bends, damage, cracks, and marks that can weaken the links.
4.6.10 Rings and hooks shall be inspected for a change in shape, cracks in the welds, and deep cuts. All
hooks, shackles, clevises shall be inspected for:
a) Cracks, twists and wear on the part that lifts the load.
b) Indications that the hook has opened more than normal or twisted more than 10 degrees
from the plane of the unbent hook.
c) Correct operation of the safety latch.
d) Wear in the top part of clevises and shackles.
e) Indications that the jaws of shackle or clevis are open more than normal.
f) Pins are of the correct type and are not worn-out or damaged.
 If any defects found during the inspection are not repairable, the equipment shall be destroyed and
discarded. Equipment with repairable defects shall be red-tagged and stored separately until
repaired.
4.7 Manpower Certification
4.7.1 Company-approved Third-Party Inspection Authority shall certify Rigging Supervisors,
Crane/Forklift Operators, Crane Safety Watchman, Signaler/Banksman, and any other personnel
deemed requiring certification in lifting operations.
4.7.2 Personnel without certification from Inspection Authority, whether Company employee or
contractor, shall not be permitted to perform critical activities during lifting operations.

4.7.3 Contractors shall provide the Company with a list of personnel with proper certification. This list will
be maintained at all Company work sites. Names of contractor operators will be checked against
this list whenever performing lifting operations.
4.7.4 Certified contracted personnel may be interviewed/tested by Company representative during the
current or subsequent assignment to Company work site. The following are guidelines for the
interview/test:
a) Operator's relevant experience for a particular job to be undertaken.
b) Previous safety performance and/or incidents.
c) Medical fitness for work.
d) Any evidence of drug or alcohol intoxication.
e) Comprehension and understanding of his task, function of the lifting equipment (for
operators), and knowledge of hand signals.
f) Observation of actual job performance.
4.7.5 Any personnel responsible for an accident involving lifting operations shall have his certification
cancelled and will have to go through a re-certification process. The Company reserves the right
to refuse deploying the involved personnel for future operations.
4.7.6 During long lifting operations such as rig moves, the operator shall be allowed two (2) 15 -minute
breaks and one (1) 30-minute meal break during the shift. Excessive operator fatigue should be
avoided.
4.8 Requirements of Lifting Appliances
All appliances working in Company Operating Areas shall display the following: -

• Manufacturer name plate

• I.D. Number

• SWL ( Safe Working Load )

• Inspection due date.

All Lifting appliances shall be inspected and tested in accordance with Section 4.6 of this Specification.

4.8.1 Cranes

Cranes shall comply with - Code of Practice for Safe Use of Cranes-Code of practice For Safe Use Of
Crane – Inspection, Testing and Examination or Mobile and locomotive cranes or Equivalent
international standards.
4.8.1.1 Mobile crane

Mobile cranes comprise prime mover (diesel engine), turn table, telescopic booms, out riggers, winches,
wire ropes, wire rope drums, hydraulic power units, hydraulic cylinders, counter weights, sheave blocks,
lifting hook blocks, wheels or crawlers, operators cabin and safety devices.

Mobile cranes can be categorized as rubber tyred and crawler types.

Rubber tyred cranes can be sub categorized as

- Rough and all terrain Diesel hydraulic telescopic boom crane.

- Truck mounted Diesel hydraulic telescopic boom crane.

- Articulated wheel mounted Hydraulic telescopic crane

Rubber tyred cranes shall work only without riggers fully extended and wheels clear of the ground.

Crawler cranes are tracked with fixed lattice type booms.

4.8.1.1.1 Load Indicators and Load Chart

All mobile cranes shall display the manufacturer Cranes Load Chart for that particular crane.

All mobile cranes shall be fitted with Safe Load Indicator. The information from the safe load indicator must
tally with the information from the crane load chart for that particular crane.

The information from Load indicator shall be as follows: -

- Tare weight

- Actual weight

 Permissible weight

 Boom angle

 Boom Length

 Boom tip height

 Radius

 Approach over load warning light

 Over load warning light

 Anti two block warning light

4.8.1.1.2 General Requirements for Operation

All cranes shall be equipped with:

1. Hoist limit device which when actuated stops the hoisting motion and applies the brake on the hoisting
winch and luffing winch automatically.
2. Engine stop system which operates in a manner such that the engine comes to rest with minimum
delay.

3. Facility for emergency lowering of loads

4. Temperature sensing device (which may be audio visual type) of equivalent safe guards to give
adequate protection to the prime mover and associate Equipment.

5. Emergency stop with manual reset capability.

6. Motion control levers which return with minimum delay to neutral upon release- (this dies not apply to
engine throttle lever)

7. Clearly tagged/marked pneumatic, hydraulic and electrical connections corresponding to the markings

on the crane circuit drawing.

8. Emergency escape route for operators.

9. Safety latches which automatically close, fitted to all integral crane hooks.

10. Suitable operating cab that protects the crane operator and controls from the elements (weather), is
adequately cooled /ventilated and provides a clear and unrestricted view of all operations associated
with the crane.

11. Safe Working Load of the hook block prominently marked and highlighted on the hook.

12. Calibrated automatic Safe Load Indicator fitted and a legible metric crane capacity chart, prominently
displayed, where the design of the crane is intended for SWL loads of greater than one (1 Tonnes).

13. Outriggers and hooks clearly marked with a red and white chevron pattern.

14. A log book in which the operator records the maintenance and safety checks and comments relating
to the crane operation.

4.8.1.1.3 Operator Checks prior to use:

The crane operator shall be responsible for correct operation of the crane. The crane operator shall ensure
that the crane is functioning correctly and properly maintained each and every time the crane is operated.
This does not in any way alleviate the responsibility of management or owner of the crane to ensure that
the Crane meets the requirements of this specification and the appropriate standards.

Where operation involves the use of a “mobile crane” in proximity to overhead power lines, it is the
responsibility of the crane operator to ensure that it is safe to do so. The crane operator shall ensure that
the equipment is operated in such a manner that NO item of “Lifting Equipment” is within 20 metres
proximity, of any live overhead power lines.

The operator shall perform the following minimum checks at the start of a working shift. The crane operator
shall record the daily checks and in the crane log book.

 Fuel

 Engine oil

 Hydraulic oil (this should be checked with all cylinders in the closed position).

 Coolant with caution the engine should be cool.

 Wire rope and drum

 Tyres

 Oil leakage

 Any other defects that is detrimental to the crane safe use

 Any faults and remedial action must be reported to the responsible person and recorded in the log
book.

4.8.2 Mobile Elevating Working Platform (MEWP)

Mobile elevating work platforms are machines that have been designed to elevate workmen and their
tools to heights to carryout temporary work. They are used instead of scaffold because erecting a
scaffold would be a long drawn affair and would not be considered a safe action for particular type of
work (i.e. Street light maintenance)

The three most common MEWP to use are

1. Scissors lift

2. Self-propelled telescopic boom

3. Truck mount articulated boom- Man lift /Bucket truck

These shall comply with BS EN 280 - Mobile elevating working platform or Personnel lifting systems or
equivalent International standards

Components are: prime mover (diesel engine), turn table, boom, stabilizers, Platform or bucket, hydraulic
power units, hydraulic cylinders and safety devices.
o
These are designed such they can rotate 360

4.8.2.1 Safety Device

All man lift shall be fitted with dead man control valve, manual over ride lowering valve and solenoid
operated lock valve fitted inlet to the hydraulic cylinder.

All man lifts shall be fitted with above devices to operate this man lifts in case of emergency.

4.8.2.2 General requirements for safe operation

Man lift shall work only with the stabilizers fully extended with the front and back wheels clear of the ground.

The man lift shall be operated in such a way that the bucket is being operated in the rear side.

All man lift shall have a log book in which the operator records the maintenance and safety checks and
comments relating to the operation.

4.8.2.3 Operator Checks prior to use:

Operators shall visually inspect the following items prior to operation: -

 Fuel

 Engine oil
 Hydraulic oil (this should be checked with all cylinders in the closed position).

 Coolant (with caution the engine should be cool).

 Tyre pressures (a critical factor in retaining the desired stability margin of the cranes).

 Oil leakage from the hydraulic systems, power units, hydraulic hose and outriggers

 Condition of battery

 Conditions of boom structures and bucket

Any faults and remedial action must be reported to the responsible person and recorded in the log book.

4.8.3 Forklift

Forklifts are machines driven by diesel or electric power, which are able to raise, lower, suspend, tilt and
move loads.

They shall comply with manufacturer’s specifications or Rough terrain Fork Lift Truck or equivalent
international standards.

All forklifts shall be inspected and tested in accordance with this specification and have a valid test
certificate.

They comprise prime mover (diesel or electric), mast structure, fork arms, counter weights hydraulic
systems (Hydraulic cylinders, power units), tyres, cabin for operator with steering.

It is a rear wheel steering machine and its centre of gravity and ground clearance are low, It shall be used
only on even and flat surfaces and not in rough terrain.

The common Fork lifts are 1. Counter balanced fork lift, 2. Articulated fork lift

The tyres can be pneumatic (air), solid, foam filled or water filled for the larger types.

They can be powered by diesel, gas and electricity (battery)

4.8.3.1 General requirement for safe operation

The Fork lift shall be equipped with :

1. Prominent marking of SWL & I.D number

2. Revolving flashing light, reverse alarm, working light

3. Fire Extinguisher (PDO approved) , seat belts

4. A log book in which the operator records the maintenance and safety checks and comments relating
to the crane operation.

4.8.3.2 Articulated type fork lift.

These differ from the counter balanced truck in that they are steered from the centre of the machine
hydraulically. They can be designed for rough terrain work .eg: rigs and can be adapted with stinger type
arms for lifting.

When lifting any load the truck should be aligned straight. No load shall be lifted when the fork lift is in an
articulated position.
4.8.3.3 Operator checks prior to use

Fork lift operators shall visually check the following items prior to operation: -

 Fuel

 Engine oil

 Hydraulic oil (this should be checked with all cylinders in the closed position).

 Coolant with caution the engine should be cool.

 Steering, foot brake and parking brake

 Lights and horn

 Fork and mast –ensure that they are not bent or damaged

 Ensure that lateral lock on fork is working

 Chain –check for worn/damaged link, ensure lifting chain anchors are secure

 Condition of tyres and security of wheel nuts

 Oil leakage from the hydraulic systems and hoses

Any faults and remedial action must be reported to the responsible person and recorded in the log book.

4.8.4 Winches

Winches are defined as machines, which are able to lift, pull, suspend and move loads.

Note: standard winches shall not be used for lifting personnel, only man riding winches will be used for
this purpose and it should be clearly marked. Also put a sign on other winches “Not for Men” and SWL to
be clearly mentioned.
They comprise rope drum, wire rope with one end permanently fitted with drum, device for rotating the
winch, and mechanical brake or ratchet type locking device.

They SHALL comply with (Mooring winches), (Hand operated plate sided winches) and (Cargo
Winches) or equivalent international standards

All winches shall be inspected and tested in accordance with this specification and have a valid test
certificate.

They can be powered by mechanical, hydraulic, electric or pneumatic and power take off from vehicle
engine.

They can be vehicle mounted (trailer) or skid mounted winches

When selecting the type of winch the following must be taken into account:

 Mounting details

 Temporary or permanent installation

 Method of operation (manual or powered)

 The types of controls or brakes (mechanical or others)

4.8.4.1 General requirement for safe operation

All winches, including pneumatic driven winches shall comply with the requirement of the specified
standard in addition to the following:

• Winch control shall be manned at all times while winch is in use.

• All winches shall have a log book in which the operator records the maintenance and safety checks
and comments relating to the winches operation.

4.8.4.2 General requirements for man riding (personnel) winches

All man-riding winches shall in addition to requirements of clause

• Be so designed to have a safety factor of ten (10)

• Be used with a rope spooling device

• Shall not be fitted with a pawl and ratchet gear, but shall have a pool proof mechanism

• Be constructed so that the brake mechanism is permanently applied at all times when the operating
controls are in the neutral position.

4.8.4.3 General requirement for vehicle mounted winches

Only companies registered by the Company as a transport contractor are permitted to carry out vehicle
mounted winch operations

4.8.4.4 Operator checks prior to use

The operator shall visually check the following items prior to operation

• Winch rope for kinks, broken wires etc.

• Main securing plates/frames and bolts /nuts

• Conditions of Winch Brake

• Oil leakage from the hydraulic systems and hoses

Any faults and remedial action must be reported to the responsible person and recorded in the log book.

4.9 Requirements for Lifting Gears

All lifting gear shall be inspected and tested in accordance with Section 4.6 of this specification at a
maximum interval of 6 months.

All lifting gear shall be free from obvious defects. Any evidence of defects or damage shall result in the
lifting gear being immediately removed from site and destroyed.

No lifting gear shall be used out with the statutory test period.
4.9.1 Shackles

Shackles shall comply with BS 3032, BS 3551, or equivalent international standard

They are made out of high tensile steel. They can be Dee, Bow and grab types.

4.9.1.1 General requirement for safe use

• Marked with SWL, size and CE mark

• Correct size and suitable type shall be used

• No shackles shall be welded or repaired

4.9.1.2 Pre-use checks

The user shall visually check the following prior to use: -

 Body – Check for wear and corrosion

 Pin- Check for wear, straightness and thread damage

 Check the jaw opening is not altered.

Any faults and remedial action must be reported to the responsible person and recorded in the log book.
If the conditions/ faults of the shackles exceed the acceptance limit specified it shall not be used and shall
be scrapped.

4.9.2 Wire rope slings

Wire rope slings shall comply with Stranded steel wire rope –Specification for general requirement and
purpose or equivalent international standard.

They are high tensile steel wire rope with soft or hard eyes secured by ferules and may be single leg or
multi leg.

4.9.2.1 General requirement for safe use

• It shall be noted that SWL decreases as sling leg angle increases

• They shall be die stamped with SWL,I.D Number and angle (0-90 degree)

• Any sling passing through sharp object shall be protected with the use of softener.

4.9.2.2 Pre-use checks

The users shall visually check the following prior to use: -

 Condition of ferrules – mechanical damage, cracks and deterioration

 Condition of wire ropes - check for broken wires, corrosion, kinks, crushing, external & internal
corrosion and core damage, reduction in diameter.

 Condition of master link assembly

Any faults and remedial action must be reported to the responsible person and recorded in the log book.
If any of the conditions exceed the acceptance limit specified the sling shall not be used and shall be
scrapped.
4.9.3 Webbing slings

Webbing slings shall comply with– Flat webbing sling and –Round webbing sling or equivalent
international standards.

They are made up of stitched woven webbing which may have a soft or hard eye. They are manufactured
from Polyamide (nylon) , Polyester and Polypropylene.

They may be flat woven webbing (belt sling) or round webbing. They may be in the form of single leg or
endless type.

4.9.3.1 General requirement for safe operation

 Webbing slings shall be stored away from direct sunlight and heat to minimize the effect of ultraviolet
deterioration.

 They shall not be used in knotted or twisted condition.

All webbing slings have a label with the following information:

 I.D. Number or Serial Number

 Working load limit(WLL) or safe working load (SWL)

 Constituent material

 Effective working length (EWL)

 Safety factors (7:1)

 Name and address of manufacturer

4.9.3.2 Pre-use checks:

The user shall visually check the following prior to service: -

 Damaged stitching

 Cuts and abrasion

 Degradation due to exposure to ultra violet rays

 Damaged end fittings

 Oil or chemical attack

Any faults and remedial action must be reported to the responsible person and recorded in the log book.
If any of the conditions exceed the acceptance limit specified the sling shall not be used and shall be
scrapped.

4.9.4 Eye Bolts

Eye bolts shall comply with BS 4278 or equivalent international standards

They are generally made from high tensile steel forging with a machined thread

They can be collar type, dynamo type or link type

4.9.4.1 General requirement for safe operation:

 Eye bolts threads shall be fully tightened so the collar contacts the object intended to lift

 No eye bolts length shall be altered or welded

4.9.4.2 Pre-use checks:

The user shall visually check the following prior to use: -

 Wear in eye and link

 Nicks, cracks and gouges in shank and eye or collar junction

 Distortion in any axis or thread bends, excessive wear or corrosion.

Any faults and remedial action must be reported to the responsible person and recorded in the log book.
If any of the conditions exceed the acceptance limit specified the eye bolt shall not be used and shall be
scrapped.

4.9.5 Chain slings

Chain Slings are generally prohibited for lifting and shall not be used unless subject to
specific dispensation by the Company on a case by case basis.

4.9.6 HOOKS

Hooks shall comply with equivalent International Standards. They are made from high tensile

steel forgings.

The most common chain hooks are sling hooks, foundry hooks, safety sling hooks, clevis sling hooks, grab
hooks, self-locking hooks

4.9.6.1 Pre-use checks:

The user shall visually check the following prior to use: -

 Throat opening and twist

 Wear in eye and saddle

 Cracks, nicks, scores, gall marks in body.

 Damage or missing locking devices (safety latches)

Any faults and remedial action must be reported to the responsible person and recorded in the log book.
If any of the conditions exceed the acceptance limit specified the hook shall not be used and shall be
scrapped

4.9.6 Sheave blocks / Snatch blocks / Pulley blocks

Sheave blocks shall comply with manufacturer specification.

The blocks generally consist of shell or side plate, centre pin, end fittings (such as hook, shackle) and a
becket or mouse ear to affix the rope line to the block.

The blocks can be single, double, triple etc according to the number of sheaves.
4.9.6.1 Pre-use checks

The user shall visually check the following prior to use: -

 Damaged or excessive wear on sheaves, centre pin and end connections

 Rotation of sheave

 Smooth sheave grooves

 Deformation of hook and centre pin

 Any faults and remedial action must be reported to the responsible person and recorded in the log book. If
any of the conditions exceed the acceptance limit specified the block shall not be used and shall be scrapped.

4.10 Inspection Frequencies and Color Coding

4.10.1 Inspection frequencies

Any Items of “Lifting Equipment “not holding valid certification shall not be utilized. Original or approved
copy of valid certificate must be available at the site where Lifting Equipment is in use. The mandatory
inspection and testing intervals pertaining to all lifting equipment are summarized in table below

S# Lifting Equipment type Intervals for

Proof Load Test Inspection
1 Lifting Appliances: • Before being put
into use
• Mobile crane, Wheel Loader Every twelve
• After (12)months
• Mobile elevating working Reinstallation
platform
• After Substantial
• Runway beams, Pad eyes alteration or
major repair
• Winches , hoist (air & electric)
• Every 4 years

2 Chain blocks, pull lift, trolleys • After

Reinstallation
Every twelve (12)
• After Substantial months
alteration or
major repair

• Every 4 years

3 Lifting Gear:

• Wire rope and chains • Before being put

into use
• Wire rope, chain and webbing Every six (6) months
slings • After substantial
alteration or
major repair
 • Shackles. Eye bolts, hooks,
rings, links, blocks, snatch
blocks

All lifting equipment is to be fully inspected and certified before put into service, and at all subsequent
periodic inspections.

The inspection frequencies are

• Every 12 Months for Lifting Appliances

• Every six month for Lifting Gear

4.10.1.1 Lifting Appliances

The first and all subsequent inspections shall include all functional tests, over load and safety tests.

Periodic inspection shall include:

A ”thorough inspection” of all components

“Non destructive testing“ of all lifting connections, attachments and structural components as necessary

Following of major repair the periodic inspection shall include a thorough inspection of all internal parts
and components complimented by a “Proof Load Test”

All Lifting appliances shall be inspected and functional tested by a competent operator for correct
functioning (special attention shall be paid to safety systems) at intervals not exceeding seven (7) days.
Where the Lifting appliance is subjected to infrequent use, it shall be inspected and function tested, by a
competent operator before each occasion on which it is used

4.10.1.2 Lifting Gear

The first inspection for all lifting gear shall be performed at the vendor, manufacturer or factory premises
and shall consist of a Proof Load Test and inspection after the test, witnessed and certified by an approved
certification authorities.

The subsequent periodic inspection shall include a through visual examination, which will be
complemented by a '‘Proof Load Test'’ when repair or modification have been conducted. These shall be
witnessed and certified by an approved certifying authority.

All Lifting Gear shall be subjected to pre-use checks by a competent rigger, each and every time it is used.
Where in the opinion of the rigger it is unsafe to use, that item will be immediately removed from the work
site and referred to inspection.

4.10.1.3 Proof load testing for specific Lifting Equipment

The Proof Load Testing frequencies are:

• Every 4 years for Lifting Appliances

• Once in a life time for Lifting Gear (before being put into service)

The chart detailed below, specify the minimum PDO Proof Load requirements, for the specified Lifting
Equipment
1 Chains & wire rope slings, Rings,
links, Hooks, Shackles, Swivels &
Eye bolts SWL up to 25 Tonnes (2 x SWL)

1.1 SWL above 25 Tonnes 1.22 x SWL + 20 Tonnes

2 Single sheave blocks

SWL up to 13 Tonnes (4 x SWL)

3 Multi sheave blocks with:

SWL Not exceeding 25 Tonnes Two times safe working

load (2xSWL)

3.1 Multi sheave blocks with:

SWL exceeding 25 tonnes but 0.933 x SWL + 27 tonnes

Not exceeding 160 Tonnes

3.2 Multi sheave blocks with:

SWL exceeding 160 tonnes 1.1 x SWL

4 Beam clamps & Plate clamps 2 x SWL

5 Beam Trolleys 1.5 x SWL

Chain block & Trolleys 1.5 x SWL

7 Chain Hooks and Fitting 2.0 x SWL

(Grade 80)

Chain sling (Grade 80)

8 Electric Overhead Travelling 1.25 x SWL

Crane (EOT)

9 Fabricated Pad eye and clamps 2.0 x SWL

10 Fork Lifts 1.25 x SWL

11 Lever Hoist (Pull Lift) 1.5 X SWL

12 Tirfor with wire rope 1.5 x SWL

13 Lifting beams:

SWL up to 10 Tonnes 2 x SWL

13.1 Lifting beams:

SWL 10 Tonnes to 160 Tonnes 1.04 x SWL + 9.6 Tonnes

13.2 Lifting beams:

SWL above 160 Tonnes 1.1 x SWL

14 Mobile elevated working 1.25 X SWL
platform/Man lift (Bucket truck)

15 Pedestal Crane 1.25 x SWL

16 Runway beams 1.25 x SWL

17 Floor cranes / Pallet stacker 1.25 x SWL

18 Jib Cranes 1.25 x SWL

19 Hoists (Electric & Pneumatics) 1.25 x SWL

20 Winch (Manual)/winch (Pneumatic) 1.25 X SWL

21 Winch (Man riding) 1.5 x SWL

 4.10.2 Colour Coding

All lifting gear shall be identified visually by the Colour Code system.

The Colour Code shall be painted on every piece of lifting gear. The colour shall indicate to the user
that an examination has been performed within the prescribed period.

A new colour shall be introduced every three months and each colour shall be current for a period of
6 months. The three months overlap is to ensure lifting gear is available for use at all times. There
are eight colours in the sequence and the cycle is repeated every 2 years (see figure).

Company practice is to have all available lifting gear examined and colour coded twice per year in
March and September.

Any lifting gear that does not have a visible colour band or where the colour is out of date shall not be
used. It shall be returned to the rigging store. Such equipment shall not be re-issued or used until after
satisfactory thorough examination a lifting equipment Inspector.

Painting of the colour codes shall be the responsibility of the asset custodian or his nominee and shall
be witnessed by the lifting equipment Inspector

5.0 TRAINING & EVALUATION:

For effective implementation of this procedure

 • HSE management representative of D&WE dept will ensure necessary training to staff, making
them fully aware with the requirements of this procedure, keeping in view their role responsibilities
and competence.
• Overall effectiveness of this procedure will be evaluated on annual basis.

6.0 RELATED DOCUMENTS & RECORDS:

• Mobile Crane Inspection Checklist

• Forklift Inspection Checklist
• Steel Rope Inspection Checklist
• Chain Inspection Checklist
• Ropes Inspection Checklist
• Web sling inspection Checklist
• Lifting Equipment Register