10 audit points for your crane & rigging operations: an hse perspective · 10 audit points for...

The views expressed in this presentation are that of ITI and are not necessarily the views of the ASME or any of its committees

10 Audit Points for Your Crane & Rigging

Operations: An HSE Perspective

Host: Mike Parnell

ITI President/CEO

ASME B30 Vice Chair (Cranes & Rigging)

ASME P30 Chair (Lift Planning)

A world leader in crane and rigging

training and consulting.

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Past Presentations:

Cranes, Rigging & Your Organization

Effective Crane & Rigging Training Methods for Your Employees

Heavy Intermodal Lift & Transport – Engineering Considerations

ITI Master Rigger Course: Interactive Demo

Lift Planning Considerations

Today's Presentation:

10 Audit Points for Your Crane & Rigging Operations: An HSE Perspective

(Thursday, October 18, 2012 - 3pm EST)

Upcoming Presentations:

Tackling the Challenges of Training Site Supervisors, Lift Directors, and Other Leaders

How Studies of Crane Accidents & Trends Lead to a Safer Work Environment

Mr. Parnell has a wealth of knowledge regarding cranes,

rigging, and lifting activities throughout a variety of industries.

• 30+ years learning about wire rope, rigging, load handling,

and lifting activities.

• Vice Chair of the ASME B30 Main Committee which sets

the standards in the US for cranes and rigging

• Chair of the ASME P30 Main Committee which sets the

standards for lift planning.

ASME standards are also adopted by many countries around

the world.

MIKE PARNELL – ABOUT YOUR HOST

The views expressed in this presentation are that of ITI and are not necessarily the views of the ASME or any of its committees.

7

• Audit Review

• Question and Answer

TODAY'S AGENDA

8

• Interactive Discussion

• Long-Term Mindset – Think about

Expansion, Consolidation, and Preparing

for Tomorrow

• Questions are Welcomed

• Utilize the Control Panel to:

- Type Questions into the Chat Box

- Answer Poll Questions

• Q & A Session after Presentation

QUICK TIPS

9

Ready to Go ?

• 10 Points of a

Crane & Rigging Audit

• Baseline Review

• Post Review

10

# 1 Existing Procedures

• Corporate Requirements

• Industry Guidelines

• OSHA

• Manufacturer

• Site Requirements

11

• Tasks are clearly defined

• Comprehension

• Square peg, square hole

• Assumptions vs. Facts

• Documentation

• Peer Review

• Sensible

# 2 Planning

12

• LHE

• Rigging

• Ancillary

# 3 Equipment Condition

13

• Competent personnel

• Demonstrates knowledge

• Defends equipment

# 4 Technical Performance

14

• Over-confidence

• Risk assessment

• Barricades and access limits

• Respect LHA zones

# 5 Safety of People,

Places & Things

15

• Caveman - to - Astronaut

• Spreader bars, BTHLD’s

• Approved use of LHE

• Improved angles, lowers risk

• Strand jacks or THGS instead of crane

# 6 Proper Equipment for Tasks

16

# 7 Efficiency

• Hidden costs

• Minimizes risk and employee exposure

• Product of planning, equipment selection,

personnel, methods

• Lowers risk due to changing operating

conditions

• Accident reports

17

# 8 Training of Personnel

• Training match the tasks?

• Proof of knowledge?

– Written testing

• Proof of skill?

– Field testing

• Competency 1-2 steps above task

level, can respond to problems

18

# 9 Management Support

• Lip service?

• Financial investment

• Line in the sand

• Who’s the king; safety or production?

• Trusted parent or 2-faced uncle?

19

• Findings

– Hard evidence

• Analysis

• Conclusions

– Scorecard

5 High, 1 Low

Acceptable, unacceptable

• Recommendations

Audit Items # 1 - # 9

20

Audit Section

Samples

21

Major Shipyard Owner

• 14 Yards

• 1,000+ employees

• 32 Mobile Cranes

• 84 Overhead Cranes

• 7 Tower wing-wall cranes

• 3 different states

• Govt. and Private vessel construction

• Worldwide competition

22

Test Results – Written Only

23

Rigging

Inspection

24

• Rigging with obvious damage is

generally being removed.

However, not in all cases and not

in all yards.

• One mobile crane had 6

“rejectable” pieces of rigging

onboard.

Rigging Inspections

25

• It appears that most of the reasons

that damaged rigging is not removed

from service is due to lack of

knowledge.

• Sample test results were not very

favorable in representing the

knowledge base for rigging removal

criteria.

Rigging Inspections

26

Rigging Inspections

27

• Many chain slings are mis-tagged and

need to be thoroughly evaluated.

• Much of the damage to chain slings

appears to be overload and bent links.

Rigging Inspections

28

• Some of the synthetic slings evaluated

have sunlight (ultraviolet rays) cuts and

punctures. The use of wear pads or

chaffing gear was not evident during the

five yard tour.

Rigging Inspections

29

• Drastic difference in how each

yard inspects and rejects rigging.

Yard 2 vs. Yard 8.

• Some great and some very poor.

Rigging Inspection scores a C.

• Recommend that training occur at

all levels and an aggressive

program begins to eliminate

damaged rigging.

Rigging Inspections

30

Mobile Crane

Operators

and Operations

31

• Most mobile crane operators have a

document stating “certification”.

• Some were passed for hydraulic, then

signed off for lattice boom as well!

• By observation, not all operators can

read and understand the load charts in

the cranes they operate.

MC Operators / Operations

32

• Mobile crane operations score a C+.

• Two distinct groups of operators exist

at “Client Location”; lever pullers and

journeyman operators.


33

• Lever pullers lack foundational

knowledge to realize necessary

crane repairs, limitations or

emergency response.


34


35

• Not all cranes operators can or will

defend the cranes from being

overloaded or misused.

• May consider the establishment of

Crane Operator Class A, B, C or

Levels 1, 2, 3.


36

• A JSA is not a Critical Lift Plan.

An accident will likely occur due

to lack of implementation of a

more formal lift plan process.

• Ship section turning is resulting in

95% load to the Manitowoc 888.

That is above the current 2-crane

lift guideline.


37

• Consider a SOP Crane & Rigging

Manual, which covers all cranes,

rigging, forklifts, aerial work

platforms, lift plans, maintenance,

and inspections.


38

• Consider ground compaction tests in

designated areas, and improving

foundations with piling and concrete in

specific locations.

• Mark areas for crane set-up as

appropriate.


39

Crane & Rigging

Supervision

40

• Standard Lifts with Cranes and Rigging

• 112 LPD x 1.5 Shift = 168 LPD

• 168 LPD x 250 D = 42,000 LPY/Yd

• 42,000 LPY x 14 Yds = 588,000 LPY/All

Crane & Rigging Supervision

41

• Critical Lifts with Cranes and

Rigging

• 98 Lifts per month

• 98 LPM x 12 M = 1,176

Critical Lifts / yr


42

• Need to respond to reports

about necessary crane

maintenance and repair.

• Be supportive in rejecting

damaged rigging. Find ways to

protect slings when possible.


43

• Need to really understand rigging

techniques and applications.

Consider intermediate and advanced

rigging training.

• Client is on the world stage of

shipbuilding and repair. Rig like it.


44

• Allow time for daily and monthly

inspections. Support the efforts

of your field people.

• Develop a few Level 3

Competent Persons for Rigging

Inspection.


45


46

• Current score of C+ for crane and

rigging supervision.

• Practical work is OK, but continued

use of damaged equipment, and

occasional willingness to overload

equipment needs to be eliminated.


47

• Impact areas

• Expectations of change

• Target improvement points

• Measureable results

• New deficiencies crop up ?

Action Plan

48

• 12 – 18 months

• Same auditor helps

• Measure improvements or

breakdown

• Evaluate gains and

determine any new

milestones to achieve goals

• 36 – 60 month review

#10 Post Audit Review

49

1 Existing Procedures

2 Planning

3 Equipment Condition

4 Technical Performance

5 Safety of People, Places and Things

6 Proper Equipment / Tasks

7 Efficiency

8 Training of Personnel

9 Management Support

10 Post Audit Review

10 Points Review

50

Q&A

10 audit points for your crane & rigging operations: an hse perspective · 10 audit points for...

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