Lifting training presentation

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Rigging and Lifting Course
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Course Objectives

• Understand rigging and lifting regulations and
  personal responsibilities
• Identify Safe Systems of Work for rigging and
  lifting
• Understand the importance of housekeeping
• Identify lifting equipment
• Understand the principles and terminologies used
  in rigging and lifting operation

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Course Objectives Cont..

• Understand the importance of hand signals and
  two-way radio in rigging and lifting operation
• Understand crane operating principles,
  conflicting activities, environmental factors,
  manual handling, dynamic and static factors

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Course Outline

• Module 1 Introduction
• Module 2 Rigging and Lifting Hazards
• Module 3 General Hoisting and Rigging Practices
  
• Module 4 Rigging Slings and Hitches
• Module 5 Rigging Hardware
• Module 6 Fiber Ropes, Knots, Hitches
• Written Assessment
• QA

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Introduction

• Rigging involves the use of cranes and other
  large pieces of equipment to lift
• OSHA heavily regulates this practice
• In crane operations, accidents do happen
• Majority of crane accidents resulting in
  fatalities and injuries are preventable
• More than 50 of all mobile crane accidents are
  the result of mistakes made when the crane was
  being set up.
• All of these accidents are preventable by
  following the manufacturers recommendations for
  assembly and dismantling, by using the correct
  components, and by observing the necessary
  precautions.

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Rigging and Lifting Hazards

• Fall Hazards created by
• Uneven working surfaces.
• Wet and slippery working surfaces.
• Working surfaces not cleared of obstructions.
• Improper use of portable ladder.
• Unprotected sides, bulkhead openings, deck holes
  more than 5 ft.

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Hazards Cont..

• Struck-by and Crushing Hazards created by
• Gear and equipment not properly inspected.
• Defective gear and equipment.
• Moving parts and equipment.
• Loads not safely rigged before being hoisted.
• Improper use of tag line allowing hoisting
  material to swing out of control.
• Loads swung or suspended overhead.
• Hazardous locations between a swinging load and
  fixed object.

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Hazards Cont..

• Electrical Hazards created by
• Use of hoisting and hauling equipment near
  energized lines.
• Tools and equipment not properly grounded.
• Defective electrical tools.
• Worn or frayed electric cables.

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• General Hoisting and Rigging Practices

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Approved Code of Practice (ACoP) Duties of
Principal

• Principals engaging contractors are required to
  take all practicable steps to ensure that
• No employee of a contractor or subcontractor, or
• If an individual, no contractor or subcontractor
  is harmed while doing any work that the
  contractor was engaged to do.

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Approved Code of Practice (ACoP) Duties of
Self-Employed

• Every self-employed person shall take all
  practicable steps to ensure that no action or
  inaction of the self-employed person while at
  work harms the self-employed person or any other
  person.

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Approved Code of Practice (ACoP) Duties of
Employees

• Every employee shall take all practicable steps
  to ensure
• Their own safety while at work (including using
  protective clothing and equipment)
• That no action or inaction of theirs while at
  work causes harm to any other person

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Rigging and Lifting RegulationsPersonal
Responsibilities

• Stay safe and remain alert in sites/facilities
• Understand and abide to company safety policies
• Abide to warning signs pasted in sites/facilities
• Use PPE and equipment as instructed
• Report all hazards
• Report and document all defects immediately
• Never throw items from height
• Only competent people are allowed to operate
  equipment and machineries
• No horseplay in sites/facilities

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Occupational Safety and Health Administration
(OSHA)

• Code of Federal Regulations (29 CFR)
• General Duty Clause
• (a) Each employer
• (1) Workplace free from recognized hazards
• (2) shall comply with occupational safety and
  health standards
• (b) Each employee shall comply with occupational
  safety and health standards and all rules,
  regulations, and orders
• (c ) Equipment provided must be
• (1) Suitable for the intended use
• (2) Safe for use
• (3) Used only by competent people
• (4) Accompanied by suitable safety measures,
  e.g., protective devices, markings, warnings

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29 CFR Occupational Safety and Health Regulations
(OSHA Standards)

• 1910 Occupational Safety and Health Standards

1926 Safety and Health Regulations for
Construction

• Subpart N Materials Handling and Storage
• 1910.179 - Overhead and gantry cranes.
• 1910.180 - Crawler locomotive and truck cranes.
• 1910.184 - Slings.

• Subpart N Cranes, Derricks, Hoists, Elevators,
  and Conveyors
• 1926.251 - Rigging equipment for material
  handling.
• 1926.550 - Cranes and derricks.
• 29 CFR 1926 Subpart CC, Cranes and Derricks in
  Construction

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OSHA 1910.184 -ASME B30.9

• Reasons
• Ensure safe equipment
• Gain knowledge and experience
• Nature of lifts being made
• Sling usage
• Operator competence
• Inspections
• Daily / Periodic before use
• Minimum annual with records
• Frequently, as warranted

• Record Keeping
• Most recent report
• Test certificates

When was the last INSPECTION performed?
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Management Of Health Safety at Work Regs. 1992

• Risk Assessment
• Record findings of that assessment
• Assessment reviewed and modified
• Suitable and sufficient risk assessments should
• - be carried out by a competent person
• - ensure all relevant risks or hazards are
  addressed
• - determine the likelihood of injury or harm
  arising
• - take into account any existing control
  measures.

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Safe Systems of WorkPermit to Work (PTW)

• What is PTW?
• Formal written authority to operate a planned
  procedure, which is designed to protect personnel
  working in hazardous areas or activities.
• PTW validity?
• Lasts for one working shift or should not exceed
  16 consecutive hours

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Safe Systems of WorkPermit to Work (PTW)

• Receiver of PTW?
• Company employees certified by department head to
  sign and receive work permits
• Sponsoring organization heads (contractor)
• Cancellation/Suspension of PTW
  a. Job safety does
  not meet the conditions specified on the work
  permit.
  
  b. Emergency situation.

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Safe Systems of WorkToolbox Talk

• What is Toolbox Talk?
• Safety lecture to educate workers about safe work
  conditions
• Also knows as Toolbox Meeting or Tailgate
  Meeting
• Required to be carried out for all work with
  significant safety exposure
• Final check in the hazard assessment process and
  the start of work implementation

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Safe Systems of WorkToolbox Talk

• When does it take place?
• Must take place at job site with all workers
  before starting the work
• Must take place at job site when major changes or
  different phases of work is started

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Safe Systems of WorkToolbox Talk

• What are being discussed/covered
• Work plan
• Hazards and Controls
• Roles and Responsibilities
• Emergency procedure
• Personal protective equipment
  
  Previous
  incidents and lesson learn
• Questions resolution of issues raised by worker

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Safe Systems of WorkToolbox Talk

• What are being discussed/covered
• Work plan
• Hazards and Controls
• Roles and Responsibilities
• Emergency procedure
• Personal protective equipment
  
  Previous
  incidents and lesson learn
• Questions resolution of issues raised by worker

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Safe Systems of WorkExample of Toolbox Talk
Checklist
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• Importance of Good Housekeeping

• Housekeeping must be carried out before, during
  and after rigging and lifting activity.
• Good housekeeping
• Ensure items are securely stored to avoid
  hazardous situations e.g. fire hazards
• Ensure equipment and accessories are well kept
  and maintained with time
• Reduce injuries e.g slipping and tripping due to
  oily/wet floor

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Examples of Good Housekeeping
Poor housekeeping and work procedures due to
inadequate site and work area supervisions
Equipments and materials are organized and stored
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Examples of Good Housekeeping
Good housekeeping ensures safe workplace
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Lifting Hardware and Equipment

• Lifting Equipment comprises of
• Lifting Appliances (equipment performing the
  lifting)
• Lifting Accessories (devices which connect the
  load to the Lifting Appliance)
• Lifted Equipment

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Lifting Accessories

• Wire rope
• Shackle
• Webbing sling
• Container
• Chain block, lever hoist and tirfor
• Hook
• Eyebolts
• Snatch block

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Components of Lifting Equipment
3/4 - 6 x 19 - FC 5/8 - 6 x 37 - IWRC
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Components of Lifting Equipment
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Components of Lifting Equipment
Ferrule

• SWL (safe working load)
• Serial Number
• Date Manufactured
• Color Code

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Wire Rope Safe Working Load

• Specified Breaking Strength
• Safety Factor

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Kinking is caused by Loops that have been drawn
too tightly as a result of improper handling
Kinks are permanent and will require that the
rope, or damaged section, be taken out of service
Wire Rope Defects of Wire Rope Sling
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Wire Rope Defects of Wire Rope Sling

• Bird caging is caused by the rope being twisted
  or by a sudden release of an overload
• The rope, or the affected section, must be
  replaced

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Wire Rope Defects of Wire Rope Sling

• Corrosion is often due to
• Inadequate lubricant
• Improper type of lubricant
• Improper storage
• Exposure to acids

• Core protrusion can be caused by shock loads
  and/or torsional imbalance
• This condition requires that the rope be taken
  out of service

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Wire Rope Defects of Wire Rope Sling

• This is often the result of heavy loads over
  small sheaves. These breaks being caused by
  strand nicking resulting from the heavy loads.

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Wire Rope Good Storage System
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Wire Rope Care and Maintenance

• Purpose of Lubrication
• Initial factory lubrication will not last
• Good Lubricant Characteristics
• Corrosion resistance
• Water repellant
• Penetrating ability
• Temperature stability
• Lubricant Frequency
• Recommended at least quarterly
• Depending on the usage
• Working environment

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Wire Rope Pre-Use Checks

• SWL is adequate for the load
• Color coding (where applicable)
• Plate number / ID mark
• Each individual leg along its entire length
  Wear, corrosion, abrasion, mechanical, damage,
  broken wires
• Ferrule should be free from cracks or other
  deformities
• Examine master link assembly (wear, corrosion,
  cracking)

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Shackle Types of Shackle
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Parts of Shackle
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Defects of Shackle
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Shackle Pre-Use Checks
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Shackle Unsafe Practices
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Shackle Good Storage System
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Webbing Sling Types of Webbing Sling
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Webbing Sling S.W.L/Safety Factors
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Defects of Webbing Sling
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Webbing Sling Pre-Use Checks

• SWL is adequate for the load
• Color coding (where applicable)
• Plat number / ID mark
• Cuts, tears or chafing
• Burst stitching (especially round the eyes)
• Chemical damage
• Ingress of foreign bodies into the fibers
• Distortion / wear in the metal eyes (where fitted)

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Webbing Sling Good Storage System
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Container Types of Container
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Markings on Container
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Markings on Container
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Container Pre-Slungs
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Chain Block - Functions

• Chain block is main for lifting
• Safety latches must be fitted on the hook
• Design for one person to pull
• Do not overload
• No suspended load

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Level Hoist - Functions

• Lifting devices operated with a handle instead of
  hand chain
• Not available in very high capacities (not more
  than few tons)
• Short load chain
• Used for short lifts
• Commonly abused (attempt to get more leverage by
  extending the
• handle with a piece of pipe)

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Level Hoist - Tirfor
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Chain Block - Pre-Use Checks

• Safe working load is adequate for the load
• Color coding is current (where applicable)
• Safety latches are fitted
• No sign of misuse
• Stretched hook
• Corroded casing
• Stretched/distorted chain.....etc.

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Chain Block - Defects of Chain
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Hooks Types of Hooks
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Hooks - Parts of Hook
Throat
Eye
Body
Saddle
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Defects of Hook
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Hooks Pre-Use Checks
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Eyebolts Types of Eyebolts
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Correct Use of Eyebolts
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Correct Use of Eyebolts
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Types of Eyebolts
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Snatch Block Types of Snatch Block
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Snatch Block Pre-Use Checks
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Snatch Block Inspection

• Side plate securing bolt cannot be fully
  withdrawn
• Manufacturer's certificate certificate of
  application
• Maintenance / inspection shall be according to
  manufacturers recommendation
• Ensure split pins, locking and secure pins are in
  place
• Ensure support structure is of adequate strength
• Consider total resultant forces acting supporting
  structure

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Rigging Principles and Terminologies
Term Description
Working Load Limit (WLL) Stated capacity of lifting equipment
Safe Working Load (SWL) The load the equipment can safely lift
Breaking Strength (BS) The actual force required to pull rigging gear to destruction
Proof Loading Proof loaded by a certified body acceptable by relevant authority
Safety factors To calculate the WLL/SWL of different types of lifting equipment.
Tare weight (TW) Weight of empty container
Maximum Gross Weight (MGW) Total weight MGW TW SWL
Included Angle Angle created between the sling legs
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Angles and Tension in Slings

• Slings Angle
• 60º Attachment point A Slings length S
• 90º Attachment point A 2 x height of
  triangle H
• 120º Attachment point A ½ x Slings length
  S

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Angles and Tension in Slings
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Weight of Load

• Maximum Load W.L.L. x angle factor x reeve
  factor
• 8 x 1.73 x 0.5
• 6.92 tones
• 6.9 tones

Sling SWL 8 Tones Angle is 60º, Factor
1.73 Reeve factor 0.5
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Weight of Load

• W.L.L. weight angle factor reeve factor
• 4 1.73 0.5
• 4.62 tones
• 4.6 tones

Weight 4 Tones Angle is 60º, Factor
1.73 Reeve factor 0.5
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Sling Angle Factor
SLING ANGLE CHART SLING ANGLE CHART
Angle fromHorizontal A S.A.F. L H
90 1.000
60 1.155
45 1.415
30 2.000
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Sling Angle Factor
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Centre of Balance
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Communication

• Roles of Banks man

• Proper rigging of load
• Supervision of the rigging crew
• Ensuring that the rigging material equipment
  have the necessary capacity in safe condition
• Ensuring correct assembly of rigging material or
  equipment
• Safety of the rigging crew and other personnel
• Correct signaling during the lifting operation

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Who are Qualified to be Banks man?

• Supervisor
• Foreman
• Team Leaders
• Bosun

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Hand Signals
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Hand Signals
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Hand Signals
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Two Way Radio- Walkie Talkie

• Disadvantage
• Communication break down due to
• Garbled message
• Weak battery
• Wave interference
• Interruption
• Background noise

• Advantage
• Provide accuracy of crane movement
• Confident to carry out the operation
• Commonly use for lifting at height / blind spot
  night activities

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Awareness of Lifting Operation
Crane Operating Principles Centre of Gravity

• Centre of gravity -is the point around which an
  objects weight is evenly balanced

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Leverage Cranes

• Principle to lift load. Rotation of the upper
  works changes the location of the cranes centre
  of gravity leverage point

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Stability

• Relationship of the load weight, angle of boom
  and its radius to the centre of gravity of the
  load

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Structural Integrity

• The crane main frame, boom sections attachments
  are all considered part of the structural
  integrity of lifting

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Conflicting Activities

• Lift Plan
• Location
• Nature of activities
• Hazard
• PTW
• Toolbox talk
• Communication

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Conflicting Activities
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Environment Factors

• Internal spaces of vessels and rigs
• Transferring equipment from vessels platforms
• Moving equipment around the deck at sea
• Submerging or recovering equipment in the sea
• Vessel motion and stability
• Weather, wind and sea forces
• Seabed suction and dynamic loading
• Noise, light, spray

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ARAMCO SAFETY INSTRUCTIONS (2)

• 6. A tag line shall be long enough for the worker
  controlling it to avoid being struck by any
  movement of the load. Tag lines must be in good
  condition. Tag lines with excessive wear and tear
  shall not be used.
• 7. Personnel shall not be required or permitted
  to work, stand, or pass under a suspended load.
• 8. Personnel shall not be permitted to work,
  stand, or pass between the winch mechanism and a
  load being winched, nor in an area where the
  worker may be injured due to winch line or winch
  line mechanism failure.
• 9. Personnel shall not be required or permitted
  to work, stand, or pass within the length of a
  cable under tension.
• 10. The working load on winch mechanisms, gin
  poles, hoists, lines, slings, grommets, hooks,
  pad-eyes and fittings shall not exceed the
  labeled / tagged Safe Working Load (SWL).

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ARAMCO SAFETY INSTRUCTIONS (2)

• 11. The SWL and unique identification number
  shall be displayed on each lifting device and
  each piece of rigging hardware in order to
  facilitate tractability through the lifting
  equipment registry.
• 12. The current color code, as per SWIM /No.3
  /RMHRE/Appendix No.2, shall be displayed on each
  piece of lifting equipment.
• 13. Winch mechanisms, lines, slings, grommets,
  hooks, pad-eyes and fittings shall be thoroughly
  inspected by the operator of the equipment before
  use for evidence of overloading, excessive wear,
  or damage.
• Any rigging equipment found to be defective shall
  be immediately removed from service and either
  repaired and recertified prior to being returned
  to service or destroyed.
• 14. The SWL of a sling shall be marked on the
  sling as per SA G.I. 7.029. If the SWL is
  exceeded the sling shall be taken out of service
  and destroyed per SA G.I. 7.029.

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ARAMCO SAFETY INSTRUCTIONS (2)

• 15. When using slings, softeners shall be
  provided between the sling and sharp unyielding
  surfaces of the load to be lifted.
• 16. A sling shall not be pulled from under a load
  when the load is resting on the sling. Cribbing
  consisting of cut drill line, lumber, etc., shall
  be used to support the load and provide a space
  for sling removal.
• 17. To eliminate shock loading, all slack in the
  sling shall be taken up carefully by the crane
  operator before beginning the lift.
• 18. When using other than single leg slings for
  straight vertical lifts, the rigger shall be
  aware of the load rating changes that occur when
  different hitches are used (i.e., basket, choker,
  etc.) or when the angle of loading is changed in
  multiple leg bridle slings.
• 19. When using a choker hitch, the sling shall be
  equipped with a protective thimble, protector arc
  or sliding choker hook to reduce wear and
  abrasion at the point where the loop contacts the
  sling body.

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ARAMCO SAFETY INSTRUCTIONS (2)

• 20. When not in use, slings shall be stored in a
  dedicated storage area (rigging loft) that will
  protect the slings from damage by moisture,
  extreme heat, corrosion, or physical abuse. It is
  acceptable for rigging hardware that would create
  a hazard while attempting to store said (large
  slings for the BOP etc.), be stored in an
  alternate area, provided that the area provides
  protection to the equipment as stated above.
• 21. Leaver Boomers shall not to be used on any
  location, a Ratchet type Boomer is the only
  approved device.
• 22. Webbing, synthetic slings shall only be used
  under the permit to work system with access
  stringently controlled by storage in a secure
  area
• A. The individual identification number of each
  webbing, synthetic sling to be used shall be
  indicated on the Saudi Aramco Rig (SAR) Safe Work
  Authorization Procedure (SWAP) or contractor
  Permit to Work (PTW), refer to HSERM
  /A/A-12/SWAP.

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ARAMCO SAFETY INSTRUCTIONS (2)

• B. Each webbing, synthetic sling shall be
  inspected by a competent person before use the
  person who inspected the slings shall be
  indicated by inclusion of his full name on the
  SAR SWAP or contractor PTW.
• The term "Competent Person" is defined as A
  person who, by possession of a recognized
  pertinent degree or certificate of professional
  standing or who, by extensive knowledge,
  training, and experience, has successfully
  demonstrated the ability to solve or resolve
  problems relating to the subject matter at work.
• C. Once the task involving webbing, synthetic
  slings has been completed, the slings shall be
  inspected by a competent person before the SAR
  Safe Work Authorization Procedure (SWAP) or
  contractor Permit to Work PTW) can be closed. The
  person who inspected the slings shall be
  indicated by inclusion of his full name on the
  SAR SWAP or contractor PTW. The webbing /
  synthetic sling shall be returned to the
  designated secure storage area. Web slings should
  be stored under lock and key conditions so as to
  prevent unauthorized use.
• 23. Certified chains shall be limited to MODU
  Towing Systems, BOP Hoists, cold shucked make-up
  chains on make-up tongs and Draw-works Catheads.
• Note Certified chains are specifically
  prohibited for use in Secondary Restraint
  applications with the exception of compliant OEM
  supplied jetting line caps.

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ARAMCO SAFETY INSTRUCTIONS (2)

• 24. Defective or damaged rigging hardware, or
  rigging hardware without compliant OEM design
  certifications, shall be immediately removed from
  service and shall be destroyed to prevent further
  use. All lifting equipment removed from service
  shall be appropriately recorded in the SA Lifting
  Equipment Registry maintained by the user.
• 25. All sling types shall have identification
  information permanently affixed with durable
  identification tags or wire rope swages and shall
  be maintained by the user so as to be legible
  during the life of the sling.
• 26. Compliant sling certificates defining the
  Design Safety Factor (Minimum 51), SWL, and
  Proof Load Test (200) shall accompany any sling
  or Hoist/winch-wire, with a unique serial number
  or ID, which shall be entered into the Lifting
  Equipment Registry to ensure traceability.
• 27. Slings shall be shortened, or otherwise
  adjusted, only by methods approved by the sling
  manufacturer.

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ARAMCO SAFETY INSTRUCTIONS (2)

• 28. Slings shall not be shortened or lengthened
  by knotting, by re-splicing, or by wire rope
  clips.
• 29. Use of any slings that have been repaired or
  modified is prohibited.
• 30. Slings shall be hitched in a manner that
  provides the best control of the load.
• 31. Working conditions that may affect slings and
  other rigging hardware shall be considered, with
  special attention to temperatures, chemicals,
  abrasions, etc.
• 32. Aluminum Ferrules are specifically prohibited
  on all wire rope slings as detailed in SA G.I.
  7.029 Section-5.22.
• 33. All attaching devices (i.e., rings, links,
  coupling pins, etc.) shall be selected to provide
  capacities equal to, or greater than, the slings
  used.
• 34. Fasteners manufactured in-house from bolts,
  rods, pins, hooks, etc., shall not be used.

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ARAMCO SAFETY INSTRUCTIONS (2)

• 35. Only hooks with safety latches are to be
  used.
• 36. Horizontal sling angles less than thirty
  degrees (30º) shall not be used.
• 37. OEM Certified four (4) Part Shackles shall be
  installed on all fixed pad-eye anchor points such
  as cylinder racks, cargo baskets, HP Secondary
  Retention Sling Clamps, Man Baskets, sheave block
  anchor points, SRL anchor points and overhead
  shackle installation applications.
• Note
• Four (4) part shackles are intended for use on
  permanent/semi-permanent installations and where
  man lifting operations are taking place.
• The use of two (2) part shackles is permissible
  for standard rigging operations.
• 38. All cargo baskets, cylinder racks, sub
  baskets, tool baskets, etc., shall be an OEM
  Certified 4-Point Lift Design, with a compliant
  OEM designed data plate attached.