Lifting Procedure Rev.4 [PDF]

Zitiervorschau

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

TABLE OF CONTENTS 1.0.

INTRODUCTION.................................................................................................................. 4

2.0.

PURPOSE............................................................................................................................ 4

3.0.

SCOPE................................................................................................................................. 4

4.0.

REFERENCES..................................................................................................................... 5

5.0.

ROLES AND RESPONSIBILITIES.......................................................................................5

6.0.

5.1

Superintendent / Barge Master / Man in Charge..........................................................5

5.2

Signalman.................................................................................................................... 6

5.3

Crane Operator............................................................................................................ 7

5.4

Rigger.......................................................................................................................... 8

PROCEDURE....................................................................................................................... 8 6.1. Task Risk Assessment.....................................................................................................8 6.2. Planning of Lifting Operations.........................................................................................9 6.3. Lifting Categories..........................................................................................................10 6.4. Environmental Conditions.............................................................................................12 6.5. Risk Assessment — guidance notes.............................................................................13

7.0.

CRANE............................................................................................................................... 23 7.1. Offshore Tower Crane...................................................................................................23 7.2. Onshore Mobile Crane..................................................................................................28 7.3. Truck Loader 3 Ton Cap................................................................................................30 7.4. Crawler Crane on board of Work Barge 225 Ton Cap..................................................31

8.0.

LIFTING GEAR................................................................................................................... 32

9.0.

SAFETY FEATURES OF CRANE.......................................................................................35 9.1. General Rules................................................................................................................36 9.2. OPERATION PROCEDURE.........................................................................................38

10.0.

ATTACHMENT.................................................................................................................... 40

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

1.0. INTRODUCTION It is requirement of COMPANY to develop the Lifting procedure as a standard procedure or guideline for CONTRACTOR related to any lifting activities on Onshore (Cilamaya ORF) and Offshore (NGLA/B). This procedure will define some types of cranes, basic functions and safety features of the lifting equipment used for lifting activity on COMPANY’s area and also highlights the responsibilities of personnel involved with a responsibility for the control and use of lifting equipment in the service for COMPANY. This procedure shall be used for all lifting operations to be conducted for New Gas Sales Project at Cilamaya ORF and NGLA/NGLB. 2.0. PURPOSE The primary purpose of this document is to provide a safe practice guideline of any lifting operations within COMPANY’s onshore and offshore area for New Gas Sales Project. To ensure that lifting equipment meets the safety, integrity and examination requirements of the Lifting Operations and Lifting Equipment Regulations (COMPANY’s Golden Safety Rules and HSE Handbook 6th edition, October 2005). The main objectives on this procedure are: 1. Ensure Task Risk Assessment has been performed and approved prior to start work. 2. Ensure only competent and authorized crane operator, signalman, and riggers are permitted to perform lifting operations. 3. Ensure the lifting plan will be prepared and approval by COMPANY prior to start work. 4. Ensure adequate equipment in place. 5. Ensure crane and all lifting equipments and accessories (Slings, shackles, etc.) comply with minimum requirement and have been inspected and certified prior to the start of operation. 6. Ensure the designated area is clear and safe condition. 7. Ensure good communication and coordination within lifting team involve. 8. Ensure that any Lifting Operation must inline with the COMPANY’s “Lifting Golden Rules”, API 2C/2D, LOLER standard requirements. 3.0. SCOPE This procedure applies to any lifting operation by cranes such as tower crane, tower crane (On board of COMPANY’s platform) that will be under CONTRACTOR’s instruction during constructions activities, Crawler crane 225 Ton cap. (On board of CONTRACTOR’s Work

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

barge), Truck Loader 3 Ton Cap. and Mobile Crane 45 Ton Cap. (on Cilamaya ORF), in the COMPANY area of operations. The document covers general requirement of the lifting equipments and the personnel involved, such as roles & responsibilities, coordination communication, procedure operation and any emergency situation. 4.0. REFERENCES 4.1. Lifting Operation Procedure, Doc. No. BPI-G-PRC-254 Rev.0 4.2. Offshore Cranes & Lifting Appliances, Doc. No. GP 38-01 4.3. COMPANY HSE Handbook 6th Edition, October 2005 5.0. ROLES AND RESPONSIBILITIES Every lifting operation must be:  Properly planned by a competent person 

Appropriately supervised



Carried out in a safe manner

Lifting activities usually involve several craft disciplines and authorities. It is therefore important that any system set up to manage lifting operations safely, must recognize this inherent complexity and must ensure that roles and responsibilities and the competencies for each activity are clearly defined, recognized and that there is a shared view of interfaces and boundaries. This section details the roles and responsibilities of these "stakeholders". The generic "stakeholders" are: 

Superintendent/Barge Master/man in Charge



Signalman



Crane Operator



Rigger

5.1

Superintendent / Barge Master / Man in Charge To ensure that a safe system of work is implemented, he should have overall control of the lifting operations. He must have adequate training, experience and technical knowledge to carry out the role competently. The duties of operation Superintendent/Barge Master/Man in Charge should include: 1. The assessment of the lifting operation to cover;

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd



Planning



Selection of cranes



Selection of lifting gear



Selection of personnel



Instruction and supervision



Involve in risk assessment.

2. Consultation with other responsible bodies i.e. COMPANY Representative, CONTRACTOR Construction Manager and Platform Superintendent. 3. Ensuring that adequate inspection and maintenance of equipment has been carried out. 4. Responsible for the organization, control and safety of the lifting operation. 5. Ensuring that there is an effective procedure for reporting defects and incidents and taking any necessary corrective action. 6. Ensure that all lifting gears have valid certification. 7. Ensure all personnel involve in lifting operations are certified fulfilling COMPANY’s requirements. 8. Ensuring that work permit have been approved. 5.2

Signalman To ensure that a safe system of work is implemented, and have approved work permit. He is only one authorized to make signal to Crane Operator during lifting operations. He must have adequate training, experience and technical knowledge to carry out his role competently. The signalman will be also as a Lifting Coordinator. The signalman duty shall include :      

404662794.doc

Ensure that the appropriate lifting accessory and safe slinging technique is identified. Ensure all of personnel is detailed including duties and responsibilities of each person. Ensure no unauthorized personnel in lifting area. Ensure clear communication with crane operator, riggers and others involve in lifting operation. Ensure all proximity hazards are identified and deal with. Ensure that he is identifiable as a Signalman.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

       

5.3

Ensure the lift is carried out safely according to the specified safe systems of work As Coordinator to lifting activity. Inspects the lifting and rigging equipment. Select proper lifting equipment. Ensure that the load is well secured and the weight does not exceed the safe working load of the lifting equipment. Clear-out lifting area. Monitor weather condition. Stop lifting operation if any unsafe condition occur and report to the superintendent.

Crane Operator To ensure that a safe system of work is implemented and have approved work permit. He should has overall understanding on all lifting activity and scenario. He must have valid MIGAS certificate and must have adequate training and experience to carry out the role competently. Minimum requirement for crane operator are:  Crane operator shall be competent and has a valid MIGAS certificate.  The operator shall be familiar with operational characteristic of the crane.  The operator shall be in good health condition and has no vision deficiency. Additional requirements for offshore crane operator :  The crane operators have offshore experience with operating cranes (minimum 2 years). This requirements should also be included in COMPANY competency assessment.  The crane operators shall be equipped with & use “Hand Free” radio communications head set, SOW will require many “blind” lifts from platform, hence operators will need to have both hands on the controls at all times.. The duty of Crane Operator will include :  He must stop crane operation if he see an unsafe condition and report to superintendent or man in charge.  He shall only follow signal from the signalman.  Identify the duties, capabilities and limitations of selected lifting appliances.  Capable to build, review, and communicated Risk Assessment.  Select the most appropriate lifting accessories with regards to the Safe Working Load.  Demonstrate the use of Load Chart in order to plan the sequence of events for lifting operations.

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

           5.4

Provide a berthing plan for a single appliance incorporating multiple lifts. Understand risks and proximity hazards and implement appropriate procedures to minimize risks. Prepare a safe system of work for a simulated lifting operation and take account of all of the above. Understand Lifting Organization including Signalman, Riggers. Understand and implement emergency procedure if undesired event occurs. Understand procedure for reporting defect and incident. Ensure that the crane, engine and accessories in good condition by using inspection checklist prior start of operation and must be documented. Ensure that the weight of load does not exceed the rated capacity of the crane (boom angle and lifting radius). Observe the load and crane operation during lifting. Ensure the load chart available on crane cabin. Transfer load according to signalman instruction.

Rigger He must be certified and assessed by Third Party approved by COMPANY. To ensure that a safe system of work is implemented, he should have overall knowledge of the lifting operation procedure. He must have formal training about slinging and rigging and have adequate experience and technical knowledge to carry out the role competently. The duty of rigger will include:  Prepare proper lifting and rigging equipment such as sling, web sling, shackle, eye bolts, tag lines, etc. and ensure that these are certified and within load capacity.  Prepare material or load to be transferred.  Scheduled/arrange transferring order.  Keep the lifting area from unauthorized personnel.  Prepared appropriate PPE for the transfer.  Assist personnel to arrange their PPE and safety belt.  Communicate with Crane Operator, Signalman, Operation superintendent about number of lifting crew.  Stop the lifting if any unsafe condition occurs.  Communicate with Signal Man for readiness of each lifting capacity.  Control load movement by using tag line.

6.0. PROCEDURE

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

7.0. Task Risk Assessment All lifting operations must undergo a task risk assessment in accordance with the site Safe Systems of Work procedure(s). Generic lifting operations shall be reviewed on a regular basis to ensure that the original Task Risk Assessments remain valid. For all lifting operations, the degree of risk identified during the Task Risk Assessment shall determine the level of supervision required for the operation and the required experience of the personnel involved. In particular, the Task Risk Assessment should account for:  arrangements to ensure personnel do NOT work under suspended loads  working, attaching and detaching the load  overloading  overturning  breakdown in communication during lifting (especially blind lifting)  the environment and location  proximity hazards  pre-use checks by the operator  deterioration in the condition of lifting accessories  the experience, competence and training of available personnel. Task Risk Assessment shall specifically consider manning requirements for safe conduct of complex and blind lifts to ensure clear communication between all team members participating in the lifting operation. 8.0. Planning of Lifting Operations Following a Risk Assessment, and the preparation of a standard instruction or procedure, the person using the equipment can normally plan routine lifts on an individual basis. In any event, the person planning the operation shall have adequate practical and theoretical knowledge and experience of planning lifting operations and be competent to perform the task. The degree of planning will vary depending upon the:

404662794.doc



Type of lifting equipment



Complexity of the lifting operation



Degree of risk involved.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

As a minimum, the plan shall address the risks identified and should identify all resources, procedures and responsibilities necessary to ensure a safe operation. All lifting operations shall be: a) Properly planned by a competent person b) Appropriately supervised c) Carried out in a safe manner. To remain cognizant of this SSOW, it is recommended that the asset management compile a series of generic lifting plans to cover routine lifting duties. Prior to the commencement of any lifting operation, a pre job safety meeting shall be carried out in order to assess the suitability of the Lifting Plan and to familiarise personnel involved in the lifting operation with the risks identified. At this time, minor variations may be necessary to take account of current conditions, e.g. wind speeds; wave height, position of people deck layout etc. and these should be documented. Lifting plans involving cranes should pay particular attention to environment conditions, tidal conditions and the crane manufacturer's operating manual. The Lifting plan for Offshore and Onshore will be submitted to COMPANY in separate document. 9.0. Lifting Categories To assist with the risk assessment process, lifting operations have been divided in four categories, which are: a) Routine b) Simple c) Complicated d) Complex 6.3.1

Routine Lift 

404662794.doc

Lifts that are performed on a regular basis, which involve basic slinging practices e.g. deck operations, material transfers.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

6.3.2

6.3.3

404662794.doc



These lift activities by definition are repetitive and as such, the method statements, risk assessments, plans and any supporting procedures should be held on file.



Carried out by competent personnel e.g. deck Crew/ Crane Opr./Riggers.



Suitable environmental conditions.



Load with known and evaluated weight shape and centre of gravity



Standard rigging arrangements.



This category of lifting operations is usually implemented using generic lifting plans and risk assessments, each with clearly established criteria and limitations.



The generic plan is then reviewed at a toolbox talk prior to being implemented by appointed competent personnel.

Simple Lift 

Lifts that involve the use of basic hoisting equipment e.g. a crane or manual hoist (suspended from dedicated lifting structures such as pad eyes or runaway beams) directly above the load.



Only one item Lifting Equipment



Carried out by competent personnel e.g. Riggers, Deck Crew and others who have training in hoisting & lifting/rigging skills.



Standard rigging arrangement



Stable, known weight with adequate lifting points.



Out-with sensitive, difficult or restricted area



This category of lifting operations is usually implemented using generic lifting plans and risk assessments, each with clearly established criteria and limitations.



The generic plan is then reviewed at a toolbox talk prior to being implemented by appointed competent personnel

Complicated Lift 

Lifting Personnel



Carried out by competent Riggers/ Crane Opr.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

6.3.4



Extended duration e.g. more than 1 shift



Use of two or more items of lifting equipment (Tandem lifts)



Out-with sensitive, difficult or restricted area



This category of lifting operations require a written method statement in addition to the lifting plan, risk assessment and the approval of COMPANY Site Lifting Coordinator or the COMPANY Lifting Technical Authority (LTA).



The specific plan is then reviewed at a toolbox talk prior to being implemented by appointed competent personnel.

Complex Lift 

If a lifting job involves divers or sub-sea work or the plan indicate the selected route for the load to travel is over live plant or a confined space, it will be classed as complex.



Unknown or difficult to estimate centre of gravity



Use of two or more items of lifting equipment (Tandem lifts)



Environmental conditions liable to affect operations



Non-standard rigging or equipment



This category of lift requires a written method statement in addition to the Lifting Plan, risk assessment and the approval of COMPANY Site Lifting Coordinator or the COMPANY Lifting Technical Authority.

Minimum number of people required carrying out the complex or complicated lifts safely shall be risk assessed and established prior to start the lifting operation. Note :

Where the lifting activities – routine, simple, complicated or complex-are likely to be repeated, the assessments, lifting plans and method statements should be held on file for subsequent review and re-use.

10.0. Environmental Conditions

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

All cranes shall be operated within manufacturers’ limit and recommendations It is the responsibility of the COMPANY Site Lifting Coordinator to ensure that accurate and realistic wind speed readings using anemometer set in an appropriate location are utilized. Lifting operations shall be suspended when either design wind speeds for lifting equipment are exceeded or the following average wind speeds reach, whichever is the lower: 

Onshore Lifting – 25 knots (12.86 m/sec)



Offshore Lifting - 25 knots (12.86 m/sec) and 2 meter wave of sea

Lifting operations may be allowed to re-commence followinq: 

A formal task specific risk assessment involving Site Manager, Site Lifting Coordinator and HSE Coord. taking into consideration site conditions, industry guidelines, crane manufacturers recommendations,



type/weight/shape/ of load being lifted



An upgrade of the lift to at least "complicated".

Continuous monitoring of the weather/site conditions including wind gust speeds. The Construction Manager shall be accountable for ensuring that if lifting operations are re-commended the above items shall be considered and the appropriate limits set, understood, recorded and adhered to Before lifting operation, shall be considered the following: 

weather forecast,



sea state,



wind direction,



type of lifting appliance and operation,



visibility (especially during weathers of darkness),



urgency of need with respect to site safety

The manufacturers’ instruction must always be followed. In weather, which causes inadequate visibility, crane operations must be suspended.

404662794.doc

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

On land if there is a prolonged heavy rain, the ground may become softer than normal and by the way, affect the stability and level of the crane. No lifting during rain or immediately after; wait at least one hour after rain and check the brakes before attempting lifting operations. 11.0. Risk Assessment — guidance notes This section is for guidance purposes only. Whilst it tries to incorporate the main hazards associated with lifting operations, these notes are not intended to be exhaustive. Other equally significant hazards may be present. Where other hazards are identified, these shall be assessed in a similar fashion to those identified on the notes, with due consideration to possible causes, consequences and appropriate solutions. Planning for the worst-case scenario should ensure that all hazards have been brought to ALARP Level and the necessary mitigation actions are in place. Lifting more than one dedicated "load" at a single time ("Piggy backing") is strictly prohibited and should not be carried out under any circumstances. 6.5.1

THE LOAD

HAZARD

Load heavier than expected

Centre of gravity not as expected

Physical size

404662794.doc

POSSIBLE CAUSE 

Incorrect weight on manifest



Weight unknown incorrect estimate



Lifting equipment Overloaded



CONSEQUENCE

SOLUTION



Equipment failure



Trial lift



Load falling



Dynamometer



Equipment instability/ collapse





Personal injury

Ensure personnel emergency access route

Incorrect information supplied



Load swinging







Load striking person

Reposition lifting equipment

Incorrect slinging

Load striking plant



Trial lift





Cargo shifting in transit



Personal injury



Ensure personnel emergency access route

 

Fit tag lines Consider alternative slinging method.



Use specialised lifting equipment e.g. low headroom



Insufficient head room



Nearby plant and



Load striking plant



Load handling problems



Personnel injury

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

machinery

Load damaged

6.5.2



Transit damage.



Falling objects



Sharp corners.



Load falling.



Personnel injury.

POSSIBLE CAUSE 

Excessive wind speeds.



Poor visibility - light, mist or fog.



High sea states.



Rain, sleet or snow showers,



6.5.3



Fit tag lines



Consider alternative slinging method.



Pre-lift check



Ensure emergency access route.



Correct PPE.

Ice on load and deck/ground.

CONSEQUENCE

SOLUTION



Load swinging.



Fit tag lines



Load striking person





Load striking plant.

Use of additional /signalman / radios.



Personnel injury.



Correct PPE.



Snatch load.



Do not carry out lift.



Crane overload.



Slips trips and falls.

POSSIBLE CAUSE

CONSEQUENCE



Unaware of lifting operation.



Load striking person.



Ignore barriers.



Personnel injury.



Unaware of risks 

Lifting over the heads of persons involved in other work front in the vicinity.

Pedestrians



404662794.doc

Use of additional banksman/ radios

CONTROLLING THE AREA

HAZARD

Other work activities in the vicinity



THE ENVIRONMENT

HAZARD

Adverse weather conditions

hoist

Persons involved in lifting operation not aware of other nearby work activities.



Load striking person.



Personnel injury.

SOLUTION 

Barrier off area.



Use of additional Signalman assistance /radios.



Keep people away.



Consult Permit issuing Authority.



Check area prior to operation.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

Communication Breakdown

6.5.4



Untrained personnel.



Radio problems.



Blind lifts.

Mechanical damage



Incorrect selection of equipment.



Incorrect assessment of weight of load.



Load striking person.

Use suitably trained personnel.



Use of additional signalman assistance/radios



Load striking plant.



Personnel injury.

Incorrect selection of equipment.



Human error.



Shackles of containers unscrewed in transit.



Safety latch of hooks damaged.



Lack of maintenance.



Incorrect use of equipment.



Contact with sharp edges. General wear and tear.



CONSEQUENCE 

Equipment failure.



Load falling.



Personnel injury.

Incorrect calculations of forces.





404662794.doc



POSSIBLE CAUSE



Lifting accessories not attached correctly

Load swinging.

THE LIFTING EQUIPMENT

HAZARD Incorrect SWL



Lifting appliance not

SOLUTION 

Double check SWL required prior to lifting.



Use dynamometer/Load indicator.



Remember to include weight of accessories for lifting



Load falling.



Pre-use check.



Personnel injury.



Ensure tie -wrap/safety pin fitted to shackles.



Equipment failure



Pre-use check.



Load falling





Personnel injury.

Review and correct maintenance plan.



Review and correct storage method.



Re-position lifting



Load swinging

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

positioned directly over load.

Incorrect fleet angle

Equipment out of date

6.5.5 HAZARD Human factors (Knowledge based)

Human factors (Error based).

404662794.doc



No pre-use check



Load striking person



Load striking plant



Personnel injury



Equipment failure



Pre-use check



Violation procedure



Correct color code



Check certification

appliance prior to operation

PERSONNEL POSSIBLE CAUSE

CONSEQUENCE

SOLUTION



Inadequate training







Lack of competence.

incorrect choice of equipment.

Ensure adequate training.



Incorrect attachment of lifting accessories.





Incorrect operation of equipment.

Check competency level of personnel involved in lifting operation.



Increase supervision.



Slips



Lapse.



Mistakes.



Load swinging.



Load striking person.



Load striking plant.



Equipment damage.



Personnel injury



Incorrect choice of equipment



Pre-Job safety meetings



Incorrect attachment of lifting accessories.



Realistic time frame to perform job.





Incorrect operation of equipment

Increase supervision.



Load swinging.



Load striking person.



Load striking plant.

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

6.5.6

6.5.7



Incorrect load applied to structural component. Lifting equipment not fitted and assembled correctly

Personnel injury

CONSEQUENCE 

Dropped object



Load striking person



Load striking plant



Personnel injury

SOLUTION 

Engineering calculations



Proof load testing



Equipment fitted or fitted by, trained/competent personnel



Thorough examination by competent person prior to use



Inadequate surface loading



Mobile crane instability



Engineering calculations



Capacity for weight of load



Deck failure



Correct anchorage





Dropped object



Environmental conditions



Load striking person



Load striking plant

Spreader plates placed under load or mobile crane outriggers



Personnel injury



Soil testing

PRINCIPLES TO A SAFE LIFT

 Before the lift 1.

Ensure personnel are competent.

2.

Assess the load & identify the risks.

3.

Select the correct lifting equipment.

404662794.doc



POSSIBLE CAUSE 

Deck collapse or Ground subsidence

Equipment damage.

STRUCTURAL

HAZARD

Structural collapse



Company :

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

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BP West Java Ltd

4.

Carry out a pre-use check.

5.

Ensure lifting equipment is fitted correctly.

6.

Identify what could go wrong — take appropriate precautions.

7.

Control the danger zone during lifting operation.

8.

Prevent the load from swinging.

9.

Avoid trapping hazards & lifting over personnel.

10. Ensure there is adequate space to land the load.



After lift 1. Check equipment after use. 2. Store in correct conditions.

All Lifting Operations must have appropriate Lifting Plan in place. Important: If you find a problem stop the job and ask! Work is never so urgent or important that we cannot take time to do it safety. 6.5.8

LIFT CATEGORIZATION ASSESSMENT ROUTINE LIFTING OPERATION (Part 1)

QUESTIONS

1

Has the lifting operation been performed before?

2

Is there a documented procedure?

3

Are you experienced with all the lifting equipment to be used?

4

Has the load been checked and made ready for lifting (e.g. sea fastenings released, hold down bolts removed)?

404662794.doc

Yes

No

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

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BP West Java Ltd

5

Do you have the experience to lift a load of this weight?

6

Is there lift in area free from obstructions and other possible hazards?

7

Can the lifting operation be carried out without the use of Webbing Slings? Or is a site-specific procedure for the use of webbing slings in place?

If the answer to any of the above is "No", go to Part 2 (Simple Lift)

If the answer to all questions below is "Yes", proceed with the Routine lift. Assessment Part 1 performed by ------------------------------------------------------------------------------Job title----------------------------------------------------------------------------------------------------------------Date---------------------------------------------------------------------------------------------------------------------

SIMPLE LIFTING OPERATION

(Part 2) 1 2 3 4

QUESTIONS Do you know the weight of the load and does the lifting operation appear to be straight forward? If the load is heavier than you normally handle, do you have the relevant permission and/or permit? Is there a crane or certified support steelwork (e.g. runway beam or lifting eye) directly above the load? Does the load have certified lifting points (lifting eyes/collar eyebolts, etc.) fitted and if not, can slings be wrapped around easily (e.g. no sharp edges, load not fragile, etc.)?

5

Is there ample headroom for the lifting appliance and slings?

6

Is the lift stable (e.g. centre of gravity below lifting points)?

7

Is the lift balanced (e.g. centre of gravity in the middle) or fitted with special slings to compensate? Is the load free to be lifted (e.g. sea fastenings released, all hold-down bolts removed, not jammed, etc.)? Is the removal route clear of any obstructions?

8 9

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Yes No

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10 11 12 13

Can the removal! (lift, transfer and landing) be performed without cross hauling? Is there suitable lay down area and does the load come within the allowable load bearing capacity of the ground/deck? Are you experienced in using all the lifting equipment and gear involved? Can the lifting operation be carried out without the use of Webbing Slings? Or is a site specific procedure for the use of webbing slings in place?

If the answer to any of the above is "No" go to Part 3 (Complicated Lifts)

If the answer to any of the above is "Yes", proceed with the Simple lift Assessment Part 2 performed by ------------------------------------------------------------------------------Job title----------------------------------------------------------------------------------------------------------------Date--------------------------------------------------------------------------------------------------------------------

NOTE : To the lifting operation nominated person: If you can give solutions to the negatives in the above questionnaire to allow the lift to proceed safely, write the instructions in the box. If you cannot supply a solution, seek guidance from the Lifting Coordinator.

COMPLICATED LIFTS (Part 3) The personnel about to perform the lifting operation shall complete the table below. Tick against factors, which are applicable and specific to this lifting operation and indicate whether or not you have the relevant experience to deal with them. QUESTIONS 1

Is the lift stable? (i.e. centre of gravity below the lifting points and not offset).

404662794.doc

Yes

No

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

2

Is the centre of the gravity for the load viewed as balanced and acceptable?

3 4 5 6

Can the lift be performed without cross-hauling or being restrained? Does the load have specific lifting attachments? Is the load robust? (not fragile) Does the load have a limited surface area that will not cause instability in the wind?

7 8 9

Does the load require only one crane? e.g. no tandem lifting Can the lift be performed without rotation? Uncertified structural components- can the lift be carried out safely without the need for MHC engineering calculations

If the answer to any of the above is "No" go to Part 4 (Complex Lifts)

If the answer to any of the above is "Yes", proceed with the Completed Lifts Assessment Part 3 performed by ------------------------------------------------------------------------------Job title----------------------------------------------------------------------------------------------------------------Date-------------------------------------------------------------------------------------------------------------------Approved/Endorsed by--------------------------------------------------------------------------------------------Job Title---------------------------------------------------------------------------------------------------------------Date-----------------------------------------------------------------------------------------------------------NOTE :

To the Lifting Coordinator; If you have experience and can advise personnel involved in the lifting operation how to deal with the complication, allow the task to proceed but only under your guidance. However if you decide that the operation is out with the scope of your competence, indicate the reasons applicable in the table in Part 4 complex lifts before passing it to the Lifting Technical Authority (LTA).

COMPLEX LIFTS (Part 4) Lifting operations or conditions, which would merit additional engineering input

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LIFTING PROCEDURE

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BP West Java Ltd

REASONS FOR REQUESTING ENGINEERING INPUT 1

The lifting operation involves divers

2

The lifting operation is sub-sea

3

The load will be travelled over unprotected process plant and machinery

4

The lift involves a floating crane

5

The load is critical to business

6

The lift is in a confined space and/or an area with very restricted headroom.

7

Use of non-certified structural components, which require engineering calculations

8

Personnel Transfer / Man-riding activity where no approved site specific procedures exist

Tick box

Lifting Plan/Method Statement and Risk Assessment Part 4 performed by -------------------------------------------------------------------------------------------------------Job title----------------------------------------------------------------------------------------------------------------Date-------------------------------------------------------------------------------------------------------------------Approved/Endorsed by (delete as applicable)

12.0.

CRANE This section will be shown and described some types of cranes and its basic function for giving everyone knowledge when they are working using crane as a lifting equipment. Safety features of a crane, personnel involved and their roles and responsibilities are also important and be-focusing in this procedure.

13.0. Offshore Tower Crane This section covers offshore tower cranes and their use in the NGLA/B Platform. This crane type may use during offshore construction stage for material transfer. 7.1.1

OPERATIONS This document provides the framework and guidance for operations, maintenance and inspection activities required to ensure the continued safe operation of the tower cranes in an offshore environment. This section

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BP West Java Ltd

applies to the offshore tower-mounted revolving cranes on fix offshore platforms, which retain the same fundamental characteristic. This type of crane is basically powered by internal combustion engines or electric motors and utilizes drums and ropes for hoisting. Operating Practices

404662794.doc

o

The qualified operator (here in also called operator) is responsible for those operations under his or her direct control. Whenever there is any doubt as to safety, the operator should have the authority to STOP and REFUSE to handle loads or continue operations as safety dictates.

o

The operator should be aware of the operating characteristics of the crane. Mechanical and non mechanical cranes will require different operating techniques, especially with regards to engine speed, control arrangement and braking. The crane manufacturer should provide operating instructions or be consulted for specific information.

o

The operator should be familiar with the equipment and its proper care. If adjustments or repairs to the crane are necessary, or any deficiencies that impair safe operations are known, the crane should be taken out of service or its operations restricted to eliminate the unsafe condition.

o

Before starting the crane, the operator should verify the following: a. The pre-use inspection b. All controls are in 'off' or "Neutral" position. c. All personnel are in the clear area.

o

For mechanical cranes, the operator should operationally test the brakes each time a load approaching the rated load is to be handled. Prior to raising the load, exposed brakes should be warmed and rusted surface on the drums cleaned by raising and lowering the boom and load lines under slight brake pressure.

o

When handling loads, the operator should never start machine movement unless the load is within his range of vision or appointed signal person is within his range of vision and given the appropriate signal.

o

The operator should response only to signals only from the appointed signalman but should obey an emergency stop signal at any time, no matter who gives signal.

o

The operator should verify that the appropriate static and dynamic load charts are in place for the crane configuration in use (i.e boom length, load line reeving, counter weight etc).

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

o

Before leaving the crane's cabin unattended for a prolonged period of time, the operator should:      

o

The crane should be secured against swinging when not in use.

o

The operator should be aware of the heat sources such as natural gas engines, gas turbines, flares, or any other heat source that exhausts near the crane. Stress corrosion cracking, paint damage, accelerated corrosion, and loss of the lubrication can result in reduced service life of components.

o

If power or a necessary control function fails during operations, the operator should: 

Set all brakes and locking devices



Move all clutch or other power controls to the off or neutral position. If practical, land the suspended load by controlled lowering or stopping.



404662794.doc

Land any attached load Disengage the master clutch, where applicable Set all locking devices Put controls in the off or neutral position Stop the prime mover Assure that no component of the crane will interfere with normal helicopter flight operations or other cranes

o

Where cranes are positioned in the proximity of helidecks or approach/take off zones, they should not be operated while helicopter is landing or taking off. The boom should be positioned and secured against swinging so there will be no interference with flight operations. The operator should not be at control station/cabin during helicopter landing/take off.

o

Where cranes are to be used at night, the operator should insure that there is sufficient lighting for safe operations. The load and landing area should be illuminated.

o

The operator should keep and maintain a log of pre-use inspection with the name, date and time of inspection. This record should be kept in an appropriate location.

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

7.1.1.1

Handling the Load The rated load capacity at the working radius of the crane shall not be exceeded. Cranes and hoists shall not be loaded beyond their rated capacity for any reason other than load testing. When working at boom lengths or radius between the load figures shown on a crane's load capacity chart, the next lower capacity rating shall be used. It is dangerous to guess the capacity for boom lengths or radius between those listed on the load capacity chart. Crane lifting capacities are based on relative motion conditions between the crane and the load to be handled. All cranes shall have one static and at least one dynamic load rating chart, derived in accordance with the procedures outlined in API Specification 2C, latest edition. The appropriate load-rating chart for the configuration in use shall be visible to the crane operator at the control station. The operator should verify that the hook load is within the crane's applicable Static or Dynamic Rated Load at the radius at which the Load is to be lifted. The crane manufacturer's operating notes and instructions supplied with the machine contain important information concerning proper set-up, operation and additional points that need to be considered when calculating load handling Capacities of cranes. The manufacturer's operating notes and instructions must be available and should always be kept with the crane. Several factors should be considered when calculating a crane's load capacity, including: 1. Load Radius: the horizontal distance between the center of the crane rotation and the center of the load. The greater the radius, the lower the capacity. 2. Boom length: including the jib, swing away extension or any other attachments that may increase length of the boom. Generally, the longer the boom length, the lower the capacity. 3. Boom angle: the angle formed between the horizontal plane of rotation and centerline of the boom. The flatter the angle, the lower the capacity.

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LIFTING PROCEDURE

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BP West Java Ltd

4. Weight of any attachments: jib, lattice extension or auxiliary boom point. The heavier the attachments, the lower the capacity. 5. Weight of handling devices: ball, block, and/or any necessary rigging. The heavier the devices, the lower the capacity. 7.1.1.2

Attaching the Load The load should be attached to the hook by means of slings or other suitable devices. The latch should be dosed to secure loose slings. The hoist rope should not be wrapped around the load.

7.1.1.3

Moving the Load No external forces should be applied to suspended loads that will create significant side loading of the boom. Care should be taken when swinging the crane so as to minimize the pendulum action of the hook and suspended load. Cranes should not be used for dragging loads unless properly rigged for a vertical pull not exceeding the rated capacity. The operator should be aware of the effect of velocity and weight of the load when lowering to minimize shock load. The operator shall not hoist, lower or swing while any personnel are on the load or hook (other than in the personnel transfer capsule) No fewer than 5 (five) full wraps of the rope should remain on the drum(s) in any operating condition. Due consideration should be given to hoist manufacturer's recommended practices, especially for break away anchor-type hoists. When two or more cranes are used to lift one load, one qualified operator should be responsible for the operation. The responsible operator should analyze the operations, and instruct all personnel involved in the proper positioning, rigging of the load and the movements to be made. Appropriate tag or restraining lines should be used where necessary to control the load.

7.1.1.4

404662794.doc

Safe Working Load (SWL)

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

The maximum load as certified by manufacturer/competent person and shall be observed during lifting operations. 7.1.1.5

Load Test A crane load test is required under the following conditions: 1. New cranes being placed into service 2. Crane that are being permanently relocated 3. Temporary cranes after each rig-up or relocation

7.1.2

SIGNALS Signals between the crane operator and the designated signalman should be discernible, audibly or visually, at all times. The operator should not respond unless signals are clearly understood. 7.1.2.1

INSTRUCTION If It is desired to give instruction to the operator other than those provided by the established signal system, the crane motion should be stopped.

7.1.2.2

SIGNALLING When operations are required to be controlled by signals, a designated signal person should be assign to work with the crane. The designated signalman should: 

Be qualified by experience with the operations and knowledgeable of the standard hand signals as shown in Attachment-7.



Be in clear view of the operator to ensure their signals can be seen. Their position should give them a clear view of the load, crane, personnel and the area of operations. If the operator's view of the primary signal person is obstructed, and additional person should be provided.

14.0. Onshore Mobile Crane The requirements operation will be same with offshore tower crane exception this crane will be used on land.

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LIFTING PROCEDURE

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BP West Java Ltd

Mobile Crane is the other common crane, on land, which are normally fitted with telescopic jib. They travel from site to site to perform lifts and usually have to put down outriggers before lifting. Their ability to move with a load is very limited and so they are generally restricted to lifts within their safe operating radius in any particular location. 7.2.1

7.2.2

REQUIREMENTS 

The Crane shall be certified by the authorize body



The crane shall be inspected and approved by COMPANY



Annual inspection shall be applied by authorize third party



Load indicator shall be installed and annual calibration by authorize third party.



TRA shall be approved before lifting operation



Lifting plan shall be prepared and approved by COMPANY before lifting operation.



Safety talk/tool box meeting shall be conducted prior to lifting operation.

LIFTING OPERATION Accidents can be avoided by careful preplanning of the job. Each lift shall be under the direction of a designated lift leader. The designated lift leader must have a clear understanding of the work to be performed and consider all potential dangers at the job site. A safety plan must be developed for the job and must be explained to all personnel involved in the lift. Keep the operator's area free of water, oil, and debris that could cause hands or feet to slip from the controls. Keep the operating cab. windshields clean and free of anything that obstructs vision. Ensure proper functioning of the crane. If at any time a crane is found to be in need of repair, is defective, or is in any way unsafe, take the crane out of service until it has been restored to safe-operating condition. Where there is a rotating superstructure, barricade the accessible areas within the swing radius of the rear of the rotating superstructure of the crane to prevent anyone from being struck or crushed by the crane. Do not hoist one load on the main hoist and another load on the auxiliary hoist at the same time. Ensure that fire extinguisher is installed at the operator station.

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LIFTING PROCEDURE

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BP West Java Ltd

Do not store gasoline, acids, caustics, or cleaning solvents that emit toxic fumes in operating cabs. Store fuel in safety cans in safe locations. Do not store any loose items in the cab. Position the crane on a solid and level footing. It may be necessary in certain situations to use heavy timber mats to build a good working foundation. The surface area of the mats should be 3 times the surface area of the crane outrigger pads. When swinging the crane, watch out for centrifugal force. Swing the crane slowly to avoid an outward swing of the load. Start and stop the swing slowly. Attach tag lines to the load to control the swing. Watch for boom kickback. Never operate with the boom at a higher angle than shown on the crane capacity charts. Use power lowering when lowering loads. When lowering heavy loads, keep the hoist brake as reserve. Use a safety pawl on the boom-hoist drum when not lowering. Avoid two-blocking, caused when the hook block makes contact with boompoint sheaves. A continuing pull on the hoist lines can break the rope or pull the boom back over the cab on some types of booms. On hydraulically telescoping booms, be sure to play out the hoist line when extending and spool in the hoist line when retracting. On hydraulically telescoping booms do not rely on the anti two-blocking device as an operating control. No one, except instructor or designated person should be allowed on a crane with the operator when the crane is in operation. No one is allowed on the crane without the operator's permission. Do not leave your position at the controls while the load is suspended, unless required to do so by an approved emergency procedure. 15.0. Truck Loader 3 Ton Cap. The crane is mounted on the truck and will be used for loading and unloading material/equipment purpose from/to truck’s basin. This Truck Loader will be used for onshore lifting only. Special attention must be paid to the following factors: 1. The ground must be sufficient firm to take up the pressure from the stabilizer legs. 2. The ground may not be slippery (i.e. covered with sand). When the parking brake is applied the truck must be able to take up the horizontal forces from the loader without skidding or moving. 3. The truck must be parked in such a way that the operator has a complete view of the field of operation.

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4. The operator must make sure that there are no electric wires or any other obstacle within the working radius of the loader. 5. The operator must inform by unauthorized persons that entry into the working area is not permitted. 6. The stability of the vehicle and the load is based on the stabilizer leg in their extreme position, and the loader should only be used at maximum stabilizer spread. The stabilizers should be lowered just enough to raise the truck chassis a little in its suspensions. 7. The tyres must still have full contact with the ground. During loading of the truck, the stabilizer legs must be raised from time to time, to ensure that the weight of the load is carried by the truck and not by the stabilizer legs. The stabilizer legs are not designated to support this excessive load. 8. The best possible loader operation will be achieved when vehicle is positioned as close to horizontal as possible. Therefore, the vehicle should be leveled to horizontal position by means of the stabilizer legs before the loader is operated. 9. If the ground is not form enough to take up the pressure of the stabilizer legs, a steel plate, or the like must be placed under the foot plates. USING THE LOADER: The loader is designed to lift loads vertically and therefore diagonal stresses should be avoided. Consequently it is not permitted to drag loads across the ground using the extension cylinders or the slewing system. These functions may only be activated once the load is free of the ground. If the load is extended so far that the lifting capacity is exceeded, the main boom will slowly begin to sink. To stop this movement the load should be brought closer toward the loader column by means of the jib or the extension cylinder. Never stand under the boom when the loader is working 16.0. Crawler Crane on board of Work Barge 225 Ton Cap. General Lifting procedure of Barge (Baruna 3) shall be followed when performing lifting activity on barge (Attached to this procedure). The Crawler Crane is also mobile on deck of Work Barge, movement is limited to forward and backward on the deck of work barge, during lifting purpose the crawler will be secured on the deck of Work Barge before lifting operation is carried out,. When no lifting operation will be carried out, the boom is rested at boom rest. The operation of crane rated at over two tons Gross Vehicle Weight (GVW) will only be done by qualified operator who are assigned to operate the crane.

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LIFTING PROCEDURE

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The Supervisor and/or COMPANY Representative shall verify the validity of operator license and qualifications prior to the start of work. 7.4.1. OPERATION  The Work Barge will be used i.e. BARUNA 3, with the dimension, 272ft length overall, 67ft breadth and 16ft depth.  The stability of barge will be submitted to COMPANY.  Lifting procedure of Barge (BARUNA 3) shall be followed.  Load indicator shall be installed and annual calibration by authorize third party.  Lifting shall be conducted as per safe radius against load (Follow Load Chart Table), the load chart shall be posted on the crane cabin.  The unit will always be operated in accordance with the manufacturer’s operating instructions.  Crane operators will always assure themselves that the unit can be operated safely by making a complete functional check/inspection of the unit prior to the start of any work.  Crane operators are responsible to ensure the work area is free from obstructions or hazards.  If the continued safe operation of the unit is questionable, the activity shall cease until such time as the concern has been resolved by the supervisor in charge.  Crane operator shall complete a daily safety checklist.  All crane deficiencies shall be reported to the appropriate maintenance dept.  Maintenance Log Book shall be maintained.  Only authorized crane operators are permitted to operate crane. An authorized crane operator is someone who hold a valid crane operator license or meets these same qualifications through Third Party licensing approved by MIGAS and who is authorized by the facility supervisor to operate a crane.  Cranes shall be inspected and documented by the crane operator using a checklist prior to the start of operation each day. If a crane is found to be unsafe to operate it shall be posted “out of service”.  Only one person shall be designated as the signalman to the crane operator. All other personnel will stand clear. If line of sight can not be established between the crane operator and signalman, hand free audio communication should be used.  The crane operator should never start machine movement until communication with the signalman is established and understood. Obey emergency stop signal given by anyone.  All cranes shall have load charts and boom angle or radius indicators located at the crane operator’s position. Offshore cranes shall reduce the load chart value by 25% when handling dynamic loads.  The crane operator shall ensure that the weight of any load does not exceed the rated capacity of the crane during a transfer.

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LIFTING PROCEDURE

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 All cranes shall be secured and pointed away and below the helicopter deck and the crane operator shall be outside of the crane cabin while the helicopter is operating in the area of the platform until clear from take off or shut down.  The operator shall be in the cab any time there is a load suspended from the hook except during helicopter operations as noted above.  Cranes with booms extended across process lines shall not be left unattended.  Crane shall be labeled its safe working load limit and periodically inspected and personnel shall be trained.  All crane hooks will be equipped with operating safety latches.  Lifting Plan need to be considered and must developed with Supervisor’s decision for lifting above 1000kg or any complex lifting (eg. Lifting using two cranes operation).  Other general lifting/rigging regulations and requirements must refer and comply to the HSE BP Handbook 5th edition section 2.20 and 2.21. Note : 1. During towing of work barge by Anchor handling Tug, boom crane have to rest on boom rest and applied appropriate lashing. 3

17.0.

2. If any rolling / pitching / heaving whereas make the heeling angle on the barge upto 3˚, then every lifting activities that involving crane have to be stopped. LIFTING GEAR All lifting gear (slings, shackle, work baskets, hoists and beams, and pad eyes) have to be inspected and certified prior to deploy in lifting operation. Therefore, all lifting gear should have valid/manufacture certificate c/w ID number and SWL mark. 8.1. POLICY Effective inspections of all Lifting gear is imperative for a safe operation. It is the responsibility of the user to visually inspect lifting equipment each time that it is used. This is to verity that there are no obvious defects in the equipment. 8.2. DEFINITION Lifting Equipment is defined as equipment which may be attached to and which may be below the crane hooks; or equipment which by design is to support a lifted load such as slings, shackles, work baskets; or equipment which would be utilized to raise and lower a derrick / mast or block. 8.3. LIFTING EQUIPMENT Lifting equipment is divided into three categories:

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8.3.1.

Category I – Sling / Wire Rope This category includes slings / wire rope which are subject to a high degree of wear and tear resulting from regular use. This category is inclusive of:

3 4



Wire rope slings (including those attached to the containers)



Chain slings



Eye Bolt



Shackles



Nylon, polyester belt sling



Cargo nets

All category I lifting equipment shall have an initial load test before being placed in service. Category I equipment shall receive certification annually / every year by a third party inspector with a record kept of the inspection. If the inspection reveals a defect, the equipment shall be withdrawn from service and either junked or load test to ensure that it is capable of lifting at the Safe Working Load (SWL) as originally certified. In order to readily identify Category I equipment that has been certified within any one (1) year period, a color code system shall be used (adopt BP regulation). Whenever Category I equipment is used, it is the responsibility of the user to ensure that it has the appropriate color-code. Any equipment, which has a out-of-date color code, is to be removed from service until inspected, recertified and properly color-coded. 8.3.2.

Category II – Miscellaneous Hardware This category includes all lifting equipment, which has been purchased from a bonafide manufacturer and by design is capable of making safe lifts up to the Safe Working Load (SWL). This category is inclusive of:

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

Pulley (pulley block, snatch blocks)



Eye bolts



Hooks



Come-alongs



Plate clamps (including those attached to slings)

Company :

Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd



Air tuggers



Container (including the lifting lugs)



Shackles



Other similar hardware

All Category II hardware is to be routinely inspected by the user to ensure that it is in good condition e.g. not bent, cracked, rusted or damaged; that it is rated for the intended lift and that it is appropriated for the intended use. Should the user detect a defect, which may effect the safety of the equipment, it should be removed from service and be immediately repaired or junked.

3

Category II hardware does not require color coding. 8.3.3.

Category III – Special Appliance and Fixtures This category generally includes all lifting appliances which are intended for a very specific use and which are by design, limited to a particular lift or lifted load. This category is inclusive of: 

Cargo baskets



Hoist runaway beams



Special lifting tools, supports, stands



Spreader bars



Cylinder racks



Transportable tanks

Category III appliances are designated to support a specific load or load limit. Category III lifting appliances should be marked, stamped, or stenciled to indicate the maximum load capacity or the specific use. Any equipment supplied by a manufacturer for a specific lift e.g. engine / compressor tools, spreader bars, etc. shall be used only for the specific intended purpose.

3

8.4. LOAD TEST

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

Physically loading a piece of equipment to a predetermined load to ensure that the equipment is capable of regularly lifting at the Safe Working Load (SWL) Limit. Testing shall be performed by qualified third party.

8.5. INSPECTIONS Examination of lifting equipment to ensure that it is safe for use. The inspection should also ensure that the correct lifting equipment is used. The inspection should be done by an individual who is familiar with the equipment and he work to be performed

8.6. IDENTIFICATION AND RECORDS Category 1 equipment shall be clearly identified with a stamp / identification mark noting the date the unit was put into service, ID number and SWL. 3

This stamp/identification mark is permissible in thee following areas: sling collars ; body of the equipment. The color code will follow BP regulation to indicate compliance with annual inspection and re-certification.

18.0.

SAFETY FEATURES OF CRANE In the interest of safety and to assist the crane operator, the crane has various limiting devices for the six motions to prevent damaging the crane. They are as follows: a. When jibbing up, there are limits to prevent the jib coming into contact with the back-stops. b. When jibing down, there are limits to prevent the jib angle becoming less than approx. 15 degrees to the horizontal. (This limit can be over-ridden to allow parking of the jib in the rest). c.When hoisting, there is a limit trip to prevent the hook block being pulled through the sheaves-anti two block limit. d. When lowering, there is a limit trip to prevent running the hoist rope completely off the winch drum thus losing the rope, hook block and possibly the load. e. Slewing limits area sometimes fitted but care still has to be exercised by the crane operator (and a signalman that guide the crane) to avoid striking the jib against obstructions such as other cranes and structures on the platform.

404662794.doc

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

In addition to the limit trips, other safety feature of the crane is an automatic Safe Load Indication (SLI) system backed up by visual and audible alarms. The SLI tells the crane operator of the operating radius of the crane (i.e. where the hook is), the SWL of the crane at that radius and the actual load on the hook. The visual alarm is usually set to activate at approx. 95% of the crane capacity at any given radius where the audible alarm activates at approx. 105% of the crane capacity, i.e. in an overload situation. The operating cabs will contain a fire extinguisher, smoke hood and Life Jacket. As with all lifting machines, cranes have a maximum safe working load but this depends on the number of wire rope on the block sheave. The SWL also reduces as the operating radius increase. The lifting operation shall refer to the load radius which will be posted in the crane cab. For loading or unloading a vessel, further reductions in capacity may apply due to dynamic loading caused by the weather conditions. 19.0.

General Rules 9.1.1.

Equipment 9.1.1.1. Crane certificate is valid – Crane certification must be done every three year (based on MIGAS regulation). 9.1.1.2. Engine and Crane have been inspected by competent and authorized person. 9.1.1.3. All crane shall have load charts and boom angle or radius indicators located at the crane’s operator position. 9.1.1.4. Minimum radius limit shall be installed. 9.1.1.5. An anti two block limit should be installed on load winches especially for man riding crane. 9.1.1.6. A safety latch shall be installed on the crane hooks. 9.1.1.7. All windows of the cabin shall be clear safety glass or equivalent for visibility. 9.1.1.8. A log book shall be located in the cabin. 9.1.1.9. Sling and shackle must be labeled to indicate the size and safe working load. 9.1.1.10. Lifting gears shall be used as per Safe Working Load specified on the certificates. 9.1.1.11. For Offshore Lifting, Safe Working Load to be deducted 25% of Load Chart. 9.1.1.12. Any visible damage or rapture on lifting wire shall not be used and discharge from site.

9.1.2.

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Personnel

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

9.1.2.1. A minimum of five competent personnel are required for all marine transfers (i.e. one designated signalman and one rigger on the vessel, as well as one designated signalman, one rigger and crane operator on the facility). 9.1.2.2. A minimum of three competent personnel are required for crane material transfer within the facility (i.e. one crane operator, one designated signalman and one rigger). 9.1.2.3. Respective superintendent shall assign dedicated crane operator and signalman to carry out day to day lifting operations. 9.1.2.4. Name of the assigned personnel above shall be posted on the STATION DUTY ROOSTER. 9.1.3.

Risk Assessment 9.1.3.1. Risk Assessment shall be approved and performed by lifting team, Task Risk Assessment (TRA) Team and performing authority prior to start operation on critical lift operation. 9.1.3.2. Job Safety Analysis shall be developed by lifting team and performing authority for non regular lifting activities.

9.1.4.

Communication 9.1.4.1. Written crane operation request and/or Log book is required to establish clear information. 9.1.4.2. The information shall include load type, estimated dimension, weight, number of person and recommended rigging equipment. 9.1.4.3. Lifting Coordinator shall have a marine radio for communication. 9.1.4.4. Lifting team must have radios for communication (Hazardous classified radios). 9.1.4.5. Communication between signalman and crane operator shall use standard crane operator signal. 9.1.4.6. Special signals for special condition which not cover by standard signals shall be agreed. 9.1.4.7. If there any unclear communication, crane operator shall stop the operation.

9.1.5.

Lifting Area 9.1.5.1. Lifting area shall be designated prior to start operation. 9.1.5.2. The designated lifting area shall be marked and clear form non authorized persons. 9.1.5.3. Barricade safety line shall be used to prevent unauthorized person entering the lifting area.

404662794.doc

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Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

20.0.

OPERATION PROCEDURE 9.2.1. PRINCIPLES OF LIFTING OPERATIONS All lifting operations shall be carried out according to the following sequence of actions: 

Plan the lift



Complete a risk assessment



Work with trained and competent people



Use the proper equipment



Inspect the equipment before use



Stay within loading limits



Maintain all safety devices



Obey all the rules and don’t take short cuts



Recognise change and re-assess the plan



Communicate



Stop an unsafe job



Keep out of the lifting area

9.2.2. LIFTING PREPARATION 9.2.2.1. Check Load list/Loads to be lifted. 9.2.2.2. Prepare work permit, JSA and share to all lifting team, sign and approve by operation superintendent or person in-charge / performing authority. 9.2.2.3. Select proper lifting and rigging equipment according to check list. 9.2.2.4. Inspect all rigging equipment prior to using. 9.2.2.5. Observe and clear out working area. 9.2.2.6. Inspect crane condition according to check list. 9.2.2.7. Prepare marine radios for signalman / performing authority / supervisor / crane operator and lead rigger. 9.2.3. LIFTING ACTIVITY 9.2.3.1. Start crane according to signalman order. 9.2.3.2. Observe load readiness, ensure tag line is available. 9.2.3.3. Check rigging with center of gravity.

404662794.doc

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Contractor :

EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

9.2.3.4. Check load properly rigged/secured. 9.2.3.5. Position the crane hook directly over the load to prevent the load from swinging. 9.2.3.6. Test back prior to lifting heavy load. 9.2.3.7. Start lifting and move the load to the designated area according to signalman direction. 9.2.3.8. Stop lifting if any unsafe condition occurs. 9.2.3.9. Observe and control load movement. 9.2.3.10. Observed and control boom, load line position. 9.2.3.11. Observe block position during boom up. 9.2.3.12. Tidy-up and secure material at the designated lifting area. 9.2.4. SAFETY PRECAUTION 9.2.4.1. The crane operator should never start machine movement until communication with signalman is established and understood. 9.2.4.2. Communication shall use standard hand signal and/or designated radio communication. 9.2.4.3. The operator shall be in the cab., any time a load is suspended from the hook except during helicopter operations. 9.2.4.4. Never stand or work under suspended load. 9.2.4.5. There will be no stacking of load unless prior approval has been obtained from the relevant COMPANY Person in charge and:  Equipment is specifically designated for that purpose, and suitable for stacking on offshore facilities.  Stacking is confined to pre-designated areas.  Risk assessment of stacking operations is performed and documented and shows that the risk involved in stacking and de-stacking is as low as practicable and less than the risk involved in alternative approaches.  Stacking and de-stacking is controlled by permit to work. 9.2.4.6. Riggers shall not touch a load being landed until the bottom of the load is at or below his waist height and never attempt to manually stop a swinging load. 9.2.4.7. All deck loads should be landed and positioned as much as practical with minimal assistance from riggers. 9.2.4.8. Tag lines shall be utilized only whenever indicated by the TRA review process, crane operator or rigger input. 9.2.4.9. All designated signalman must wear a distinctive color high visibility vest or jacket (color different from fire watch).All lifting team must be on position all the time from the first time the crane start until the end of operation, the engine/prime mover stop. 9.2.4.10. OIM or supervisor or person in charge of the facility will participate in facility induction and will emphasize lifting/rigging safety. 9.2.5. END TASK

404662794.doc

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

9.2.5.1. 9.2.5.2. 9.2.5.3. 9.2.5.4. 9.2.5.5. 9.2.5.6. 9.2.5.7. 9.2.5.8. 9.2.5.9. 21.0.

3

Land any attached load. Disengage the master clutch, where applicable. Secure the crane boom on the boom rest. Set all locking device. Stop the prime mover engine. Clean and clear lifting area. Tidy-up and secure material at the designated area. Restore rigging tool at the designated location. File document.

ATTACHMENT 10.1

ATTACHMENT – 1

: Flow Chart for Crane Operations

10.2

ATTACHMENT – 2

: Lifting Request Information

10.3

ATTACHMENT – 3

: Daily Pre-Operation Inspection Check List

10.4

ATTACHMENT – 4

: Lifting Operations (Rigging Inspection and Preparation Check List)

10.5

ATTACHMENT – 5

: Lifting Operations (Shackle & Eye Bolt Inspection Flow Chart)

10.6

ATTACHMENT – 6

: Flow Charts – Crane Pre/Daily Inspection

10.7

ATTACHMENT – 7

: General Procedures for Crane Operation and Safety

10.8

ATTACHMENT – 8

10.9

ATTACHMENT – 9

: Lay out, specification & Certificate Migas of Crane Barge Baruna 3 : Berita Acara Pengujian Beban Tower crane – NGL B

10.10 ATTACHMENT – 10 : Signal For Mobile Crane

404662794.doc

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.1. ATTACHMENT-1 Flow Chart for Crane Operation

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.2. ATTACHMENT-2 Lifting Request Information

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.3. ATTACHMENT-3 Daily Pre-Operation Inspection Check List

404662794.doc

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.4. ATTACHMENT-4 Lifting Operations (Rigging Inspection and Preparation Check List)

404662794.doc

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.5. ATTACHMENT-5 Lifting Operations (Shackle & Eye Bolt Inspection Flow Chart)

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EPCI FOR FACILITY MODIFICATION AT NGL AND CILAMAYA TO SUPPORT NEW GAS SALES PROJECT PT. ISTANA KARANG LAUT

LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.6. ATTACHMENT-6 Flow Charts – Crane Pre/Daily Inspection

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.7. ATTACHMENT-7 GENERAL PROCEDURE FOR CRANE OPERATIONS AND SAFETY

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DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.8. ATTACHMENT-8 LAY OUT, SPECIFICATION & CERTIFICATE MIGAS OF CRANE BARGE BARUNA 3

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

10.9. ATTACHMENT-9 BERITA ACARA PENGUJIAN BEBAN TOWER CRANE NGL B

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LIFTING PROCEDURE

DOC NO. : BPWJ – Z –PRC - 0004 REVISION : 4 PAGE : 91 OF 92

BP West Java Ltd

3

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10.10. ATTACHMENT-10 SIGNAL FOR MOBILE CRANE