Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
Table of Contents
1. Introduction ............................................................................................................. 4
1.1 Policy ..................................................................................................................................... 4
1.2 Scope & Purpose ................................................................................................................... 4
2. Hierarchy of lifting .................................................................................................... 5
3. Standards and Cross References: .............................................................................. 5
4. Roles and Responsibilities......................................................................................... 6
4.1 CONTRACTOR ........................................................................................................................ 6
4.2 SUBCONTRACTOR ................................................................................................................. 6
5. Gin Wheel Planning .................................................................................................. 6
6. Types of Gin Wheels ................................................................................................. 8
7. Installation ............................................................................................................... 8
8. Rope for gin wheels .................................................................................................. 9
9. Lifting Bags: .............................................................................................................. 9
10. Securing the load at the Gin-wheel station.............................................................. 10
10.1 Initial or oversized loads ..................................................................................................... 10
11. Inspection .............................................................................................................. 11
11.1 Thorough Inspection ........................................................................................................... 11
11.2 Pre-Use Check ..................................................................................................................... 11
11.3 Weekly Inspection ............................................................................................................... 11
12. Exclusion zones ...................................................................................................... 11
13. Training and Competency ....................................................................................... 12
13.1 Approval to secure loads with hitches ................................................................................ 12
13.2 Maintaining Clear Sight of Each Other (ensuring good communication) ........................... 12
14. Inclement Weather................................................................................................. 13
15. Manual Handling (chaining of materials) ................................................................. 13
16. Propriety lifting aids ............................................................................................... 14
TEP-930-GLN-HS-BP4-0003 Page 2 of 14 Rev: B01
© BP p.l.c. BP Internal
Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
Revision History
Amendment Date Revision Amender Name Amendment
Number
30-Mar-2022 B01 Louis Steven Issue for Information
Related documents
Document number Document name Description of Content
TEP-930-PLA-HS-BP4-0002 Contractor Control of Work for Greenfield
TEP-930-PRC-HS-BP4-0089 Contractor Commissioning Control of Work
for Greenfield
TEP-930-PLA-HS-BP4-0003 HSSE Plan
TEP-930-PRC-HS-BP4-0009 Construction HSE Plan
TEP-930-PRC-HS-BP4-0030 JSA Pre-Start Risk Assessment
TEP-930-PRC-HS-BP4-0047 Working at Height
TEP-930-PRC-HS-BP4-0019 Dropped Object Prevention Program
TEP-930-PRC-HS-BP4-0041 Scaffold Procedure
TEP-930-PRC-HS-BP4-0032 Lifting Procedure
Stakeholders
Name Date Reviewed
Matteo Ammirati ( Project Director Site )
Giandomenico Paone ( Construction Director)
Audrius Gudeika ( Project HSE Manager)
Rafael Aguilar Martinez (Site HSE Manager)
TEP-930-GLN-HS-BP4-0003 Page 3 of 14 Rev: B01
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Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
1. Introduction
The project acknowledges the there is a requirement to conduct the manual hoisting and lowering of
materials to and from scaffolds and other structures, when powered mechanical equipment such as
cranes is not practicable.
Manual lifting is defined as the transfer of material to or from height using manual handling
techniques, which primarily means the use of gin wheels and rope.
1.1 Policy
The project policy is that:
a. All lifting activities shall be adequately planned, assessed, supervised, and undertaken by
competent persons.
b. The method chosen for lifting and lowering of materials shall follow the hierarchy of lifting.
c. The area below any lifting or lowering activity shall be barriered off to prevent unauthorized
access.
d. In the event that powered mechanical means is not practicable, then the primary means of
lifting shall be a fixed gin wheel station, with a certified; lifting bag and lifting hook spliced to
the end of a rope.
e. Wherever a lifting gin wheel station is not accessible or practicable; than a certified handline
with a lifting hook and lifting bag shall be in situ at the access to scaffold / permanent
structure.
f. Knots and hitches shall not be used for lifting and lowering of materials or equipment.
g. Exemptions to (f) are reserved for rigging personnel who have been formally TEP assessed as
competent, and where it’s more hazardous to use a lifting bag. For example, the rigging of
chain blocks.
1.2 Scope & Purpose
This policy is applicable to all lifting and lowering of materials using gin wheels, handlines and or
manual handling.
This document is intended to provide guidance to the persons responsible for planning managing,
supervising, and undertaking manual lifting, hoisting / transfer of materials on the project.
TEP-930-GLN-HS-BP4-0003 Page 4 of 14 Rev: B01
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Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
2. Hierarchy of lifting
The responsible person shall decide on the most appropriate approach to lifting operations,
dependent on the height, complexity of lifting operations, hazards / risk and timescale.
Preference Method
1 Cranes
2 Forklift Trucks
3 Mechanical hoists
4 Gin Wheels (including proprietary gin wheels with “brakes”)
5 Hand lines
6 Manual Handling and “chaining material”
Table 1) Hierarchy of lifting
Notes on above Hierarchy of lifting:
a. Mechanical aids are preferred over manual handling to reduce the manual handling risks to
operatives, but the choice of lifting equipment must be commensurate with the risk (e.g. it
may be impracticable to arrange a mobile crane for the construction of an 8m high scaffold,
but it may be the preferred choice for very high-level works).
b. Whenever a mechanical method is used to load materials onto the scaffold, including a hoist,
crane or forklift, the materials must be loaded onto a loading bay that has been designed for
the impact load and not directly onto the access scaffold.
3. Standards and Cross References:
• BS 1692:1998, Specification for gin blocks.
• NASC SG9:21 Use, Inspection & Maintenance of Lifting Equipment and Accessories for Lifting
in Scaffolding
• NASC SG6 Manual Handling in the Scaffolding Industry.
• NASC SG26 Scaffolding & Hoists.
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Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
4. Roles and Responsibilities
4.1 CONTRACTOR
Contractor is responsible to ensure the contents of this procedure are communicated to the sub-
contractor, and to verify compliance against its contents on a regular basis. Feedback shall also be
given to the subcontractors and Company on the level of compliance and areas for improvement.
Contractor is also responsible for all training and any assessments outlined in this guide.
4.2 SUBCONTRACTOR
Subcontractor is responsible to communicate the contents to its relevant employees and implement
the requirements of this guide. In addition, the subcontractor shall conduct regular self-verification of
compliance.
5. Gin Wheel Planning
The Project considers gin wheel & rope operations to be safe and an industry standard, but
nonetheless recognizes that there is still a risk of materials falling – often due to human factors – and
this must be taken into consideration during the planning stages, and suitable measures put in place
to reduce the risk.
1. Tangguh expansion project only allow to use GIN Wheel accompany with self-locking
mechanism.
2. Side lock ( 7 figure key lock ) GIN WHEEL are not allow to be used within Tangguh Expansion
Project ( lesson Learn after Gin Wheel Fatality within BP Project in Spain )
3. Gin wheels shall only be used when considering the hierarchy of control.
4. The Installation of the Gin Wheel on scaffolds structures shall be approved by the scaffolding
engineer after calculating all potential acting forces on the structure and specifically on its
cantilevered section.
5. The Gin Wheel should be supplied with manufacture EC Declaration of Conformity certificate
or other Examination & Thorough Inspection certificate.
6. The Gin Wheel should be connected to the scaffold only after all approvals are obtained in
writing.
7. The responsible person must also decide on the required control measures, including the size
of any required exclusion zones
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Tangguh Expansion Project – LNG EPC
Safe Installation Use of Gin Wheels and Manual Lifting Guideline
Figure 1) Example planning schematic for gin wheel erection.
TEP-930-GLN-HS-BP4-0003 Page 7 of 14 Rev: B01
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
6. Types of Gin Wheels
Tangguh expansion project only authorized Self Locking Mechanics Gin Wheel to be use on side.
NOTE: Load bearing double couplers MUST be fixed either side of the Gin Wheel.
Manufacturers will state the Safe Working Load (SWL) on their gin wheel product, which may be as
high as 250kg; however, the Project stipulate that when the wheel is attached to a scaffolding tube
projecting out from the scaffold at a distance of up to 750mm the SWL for that wheel – and scaffold
– is 25kg, to ensure that there is no deflection in the tube or scaffold.
Fig 3) Ring type gin wheel
There are proprietary Gin Wheels on the market with specialist differences (such as an integral brake
system, which prevents the rope travelling when the brake is applied).
The Project recommends that when these more complex Gin
Wheels are used the subcontractor ensures that control
measures are put in place to combat any potential side effects
– such as, for instance, the potential chafing of the rope when
the brake is applied (which may require regular additional
checks/inspections) (including additional manufacturers
inspection requirements). See Fig 4 - Note the correct routing
of the rope.
Fig 4) Gin wheel with braking mechanism.
Installation
Installation of gin wheels shall only be conducted by authorised scaffolders, in line with the following:
1. Check and confirm that the suspension/anchorage position has been designed to be greater
than the SWL of the wheel/pulley.
2. The cantilever scaffolds where the Gin Wheel will be installed shall be of sufficient height
(loft) to ensure tension can be applied and that the users can maintain a safe position.
3. Mount the gin wheel on a safe work platform that is above the standing arm’s length of the
worker who will be receiving the load. The load itself should be received no higher than the
worker’s shoulder height.
4. Attach the wheel to the designated anchorage point.
5. You can either use a suitable shackle with a nut and split pin or preferably slide the loop of
the gin wheels bracket a scaffold pole and retain in place using a scaffold clip either side.
6. Only use a pully / gin wheel with a working safety catch on the lifting hook to prevent the
wheel from detaching.
7. A detail installation shall refers to SCAFFOLDING PROCEDURE ( TEP-930-PRC-HS-BP4-
0041_B09).
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
7. Rope for gin wheels
1. The diameter ratio between the gin wheel sheave and the rope should be adequate to avoid
damage to the rope or sheave. Nor to allow the rope to come out of the sheave groove.
2. Use of Manila / Natural ropes is not recommended for gin wheels, and it’s recommended to
use Man-Made fiber / synthetic slings with a manufactures certificate.
3. Make sure that you only use a suitable rope of either 18mm or 20mm, which is long enough
for the required drop.
4. The rope should be in a continuous loop with a "tail" that had a
loop at the end. See fig 6.
5. It’s recommended the loop go through the hard barricade so that
it would be easy to use the hoist while standing outside the
barricade.
6. When not in use, store the rope so that it’s protected from
prolonged exposure to environmental conditions.
7. The hoisting rope normally become worn and needs to be
removed from service, this may lead to the rope cut off during
lifting the loads and in case in contacts with sharp edges. Fig 6) Looped rope with tail
8. Rope should be clean and free from dust, dirt, moisture and
grease.
9. If the rope is gouged, twisted or frayed it should be removed from service immediately
10. All splices within the rope, or spliced eyes shall only be carried out by a competent and a
project formally approved person(s).
11. If the Rope is non-Long enough then its shall be not modified or extended without approved
from Scaffolding and / rigging competent Personnel. The best solution is to create a second
loading bay before continue hoisted materials to the designation location if the distance
beyond the reach of single line rope.
8. Lifting Bags:
1. Lifting Bags should be marked with the safe working capacity and in good condition.
2. Lifting Bags should be inspected prior & post any lifting operations.
3. Lifting Bags should be used only for steady shapes with equal size and length to ensure a
secure load and avoidance of dropped objects.
TEP-930-GLN-HS-BP4-0003 Page 9 of 14 Rev: B01
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
Figure 7) Example propriety lifting bags (SWL shall be displayed)
9. Securing the load at the Gin-wheel station.
Anything to be lifted at a gin wheel station should be secured
to the loop with a certified hook or carabiner and this Figure 7 - Spliced hook
attached to certified lifting bag of suitable size for the load.
Because of the risk of using lifting equipment, it is
recommended that the operation is risk assessed and control
measures put into place and monitored. Example illustration
of rope with a hook. (right)
9.1 Initial or oversized loads
In these cases, were there is not a bag suitable for the length or shape of the load. And providing
crane access is not practicable, then these loads shall be secured only by competent / assessed
riggers or scaffolders. Examples of such are shown below.
Figure 10) taken form GPO Dropped Object Guide
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
10. Inspection
10.1 Thorough Inspection
The subcontractor must arrange for thorough inspections every month as per Site Lifting procedure,
of gin wheels and all accessories (including ropes) Copies of these certificates must be retained. The
serial number on the Gin Wheel must be the same as the certificate.
The Gin Wheel and Rope must be fit for purpose (e.g. no cracks in the metal, no signs of corrosion, no
sharp edges, and the rope in good condition with no fraying and no cuts).
10.2 Pre-Use Check
A competent person (normally the trained user) should carry out an unrecorded pre-use inspection
of the Gin Wheel & Rope at the beginning of every shift (and continue monitoring the equipment
throughout the day).
There is a formal checklist will be provided and shall be completed by
10.3 Weekly Inspection
Once the erected, the gin wheel & rope becomes part of the scaffold and shall be inspected as part of
the weekly scaffold inspection regime – the equipment must have a weekly recorded inspection by a
competent person (e.g. a Scaffold Inspector).
11. Exclusion zones
1. The area directly underneath the rope and wheel must be suitably cordoned off to prevent
access by the others, using methods determined by the risk assessment (e.g. tube guardrails,
barriers, fencing and/or lookouts) with warning signs displayed, before work commences.
See Fig 11.
2. The integrity of the exclusion zone must be maintained, and work must cease if anyone
accesses the exclusion zone.
3. At all times the operative must have an escape
route in place in the unlikely event of material
falling from the rope, and the operative must never
stand under the hoisted load.
4. The barricading around the work zone should be
defined in-relation with the elevation height scale
within the site drop object safety barriers
requirements. See Fig 12.
5. An exclusion zone may only need to be the size of
the activity footprint, but for gin wheel operations a
larger exclusion zone may be required to provide a
suitable containment area in the event material falls. Figure 11) example lifting zone
6. Materials stored on working lifts and landing areas are to be clearly zoned off with protection
barriers and signage during operations. Material should not be stacked directly below the gin
wheel and rope (to prevent the risk of material falling from the rope and landing on the
stacked material, resulting in the stacked material being ejected towards others).
TEP-930-GLN-HS-BP4-0003 Page 11 of 14 Rev: B01
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
Figure 12) Exclusion Zone Guideline
12. Training and Competency
All those who carry out Gin Wheel & Rope operations shall be suitably trained. Suitable user training
shall be provided by contractor via its Project training courses
a. Working at Height,
b. Manual handling and
c. Safety Gin Wheel & Rope training (HOLD)
12.1 Approval to secure loads with hitches
Only riggers who have passed the TEP rigger practical assessment, which include the necessity to demonstrate
the correct use and application of hitches and knots shall be allowed to secure loads using hitches.
12.2 Maintaining Clear Sight of Each Other (ensuring good
communication)
The operatives involved in lifting operations must have clear sight of each other and maintain good
communication at all times.
They must agree on a system of verbal and non-verbal signals BEFORE work starts.
These include verbal calls as “Take the weight”, “Mine”, “Yours” and appropriate use of the rope such
as the ground man taking up the slack on the rope during the dismantle so that the top man can feel
the load being slightly hoisted. The top man will then lift the load over the guardrail – holding on to
the rope and visually checking the ground man is ready – before steadying the load and releasing the
rope. The ground man will then lower the load to the ground.
TEP-930-GLN-HS-BP4-0003 Page 12 of 14 Rev: B01
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
13. Inclement Weather
As the Gin Wheel used in high elevation levels, therefore wind speed should not exceed the
manufacture recommendations or site producers which is safer and to be covered by JHA, etc.
The sub-contractor must risk assess inclement weather and when work must cease due to inclement
weather (e.g. high winds). Employees also have a duty to contact their employer where they perceive
a risk due to bad weather.
14. Manual Handling (chaining of materials)
Chaining or handballing is traditionally the quickest method of raising and lowering scaffolding
materials to and from the work area. This
method shall only be conducted by trained
scaffolders.
It consists of operatives positioning themselves
on different lifts of a scaffold structure and
passing materials form one to the other up or
down. Lengths of material are passed through
the hands, sliding, gripping alternately. The
distance between them will vary on the length
of material; i.e 1.5m transoms will require
operatives to be on adjoining lifts and
materials 2.4m and longer will require
operatives to be on alternative lifts.
Note: The person on the floor shall not be in a
line of fire position and should remove himself
as soon as the initial load is transferred.
Operatives will develop a form of
communication to confirm that they have
taken the weight of the piece of material from
the operative passing it to them. Forms of
communication could be a light twist, a slight
pushing up of the piece of material or a shout
of mine.
Figure
13) Example of chaining material
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Safe Installation Use of Gin Wheels and Manual Lifting Guideline
15. Propriety lifting aids
A number of proprieties lifting aids for scaffold boards and tubes are available on the market, although these
can in some cases make the manual handling more difficult and increase the risk of dropped objects when
releasing the load. Therefore any use must be carefully risk assessed.
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