b-16 cranes, rigging, and lifting equipment...aug 01, 2019 · around cranes and lifting equipment....
TRANSCRIPT
Buckeye Partners, L.P. Page 1 of 13
Revision Number 01
Manual Contractor Safety Manual
Revision Date: 8/1/2019
Procedure B-16 Cranes, Rigging, and Lifting Equipment
Document Author H&S Team
Approver’s Signature
Printed copy may not be latest version.
B-16 Cranes, Rigging, and Lifting Equipment
1.0 Purpose
1.1 The purpose of this policy is to ensure that all personnel are protected from potential
hazards during lifting operations.
2.0 Policy
2.1 This policy describes the minimum safe work practices that must be followed during
lifting operations.
3.0 Scope
3.1 This policy applies to all Buckeye and Contractor personnel working with and/or
around cranes and lifting equipment.
4.0 Definitions
4.1 Cranes - A machine for lifting and lowering a load and moving it
horizontally, with the hoisting mechanism an integral part of the machine. Must be
capable of lifting more than 2000 lbs.
4.2 Rigging - Devices used to secure a load to the lifting mechanism i.e. slings, chains
and chokers.
4.3 Lift supervisor - the onsite person competent person responsible for the execution of
a critical lift.
4.4 Lifting equipment - any device other than a crane that lift equipment and materials
from one position to another i.e. telehandler boom lifts, excavators.
4.5 Hoist - a device used for lifting or lowering a load by means of a drum or lift-wheel
around which rope or chain wraps. It may be manually operated, electrically or
pneumatically driven and may use chain, fiber or wire rope as its lifting medium.
4.6 Must - Is used where a provision is mandatory.
4.7 Shall - Is used where a provision is mandatory.
4.8 Should - Is used where a provision is preferred.
5.0 General
5.1 Crane and Lifting Equipment Safety
5.1.1 Manufacturer’s specifications and limitations applicable to the operation
of all cranes and lifting equipment shall be complied with at all times.
5.1.2 Rated load capacity charts, recommended operating speeds, special hazard
warnings, and other essential information must be conspicuously posted in
all cranes and lifting equipment. Follow them at all times.
Note: Never attempt to lift more than the rated capacity of the equipment or
the attached rigging.
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5.1.3 Operators must take signals from only one qualified signal person. A
signal person must be used if the operators view is obstructed, if site
specific safety concerns require it, or if the operator deems it necessary.
In an emergency, however, a STOP signal can be given by anyone.
5.1.4 When using hand signals, only standard hand signals will be used and
acknowledged. See Exhibit A
5.1.5 Fueling must not be performed when equipment is in use.
NOTE: Repairs and maintenance must be performed off-site unless on-
site repairs are authorized by local operations.
5.1.6 Accessible areas within the swing area of the counterweight or equipment
must be barricaded to prevent personnel injury.
5.1.7 Never allow anyone to ride the hook or the load.
5.1.8 A fire extinguisher, rated at least 10 BC, must be at all operator stations or
cabs of equipment. Reference: ASME B30-5-2014 Sec. 5-3.4.9
5.1.9 Locking safety latches are required on all lifting hooks.
5.1.10 At least one tagline must be used on all loads.
5.1.11 Personnel shall keep clear of suspended loads and be aware of pinch
points.
5.1.12 The operator must ensure that loads are not lifted over people, and the path
of travel is clear of hazards and obstructions. The rigger (when there is a
rigger) and lift supervisor share that responsibility.
5.1.13 When equipment is equipped with outriggers, they must be extended fully
to realize the equipment’s full capacity. Pads or cribbing shall be used at
all times and shall be used following the manufacturer’s recommendation
for size and location. Verification of underground utilities, piping, vaults
and previous excavations shall be used when making outrigger pad
placement determinations.
5.1.14 Secure crane and lifting equipment operations during periods of storms
and lightning. Refer to Safety Manual C-22 Severe Weather for additional
guidance. Safe wind speed decisions will be made by the machine operator
utilizing manufacturer’s recommendations and the operator’s experience.
5.1.15 The operator shall never leave the operator seat with a load suspended.
5.1.16 Always enter and exit by facing the equipment and maintaining at least
three points of contact.
5.1.17 Crane operators shall be qualified/licensed/certified to the specific type of
crane being operated.
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1. Operator certification for cranes capable of lifting more than 2000 lbs.
shall be through NCCCO or NCCER or other globally recognized
equivalent. Always verify state-specific licensing requirements.
2. Operators of lifting equipment shall be qualified to operate the
specific piece of equipment.
5.1.18 Care shall be taken when operating equipment near flare stacks or other
ignition sources.
5.2 Crane and Lifting Equipment Operation
5.2.1 All outriggers on cranes and lifting equipment when applicable, will be set
and the equipment leveled for all lifts. If due to configuration or physical
location all outriggers cannot be fully extended and grounded, calculations
to determine capacity shall be made based on the manufacturer
specifications. These specifications must be provided in writing as part of
the lift plan.
5.2.2 Equipment will not be moved or positioned with the outriggers extended if
other equipment is within the exclusionary zone. Moving with outriggers
extended on location is acceptable, but will require two spotters for 360°
coverage.
5.2.3 Walking of suspended loads should be avoided. When necessary to move
a suspended load, the following applies:
1. Investigate route to be followed for solid and level footing and
overhead obstructions or power lines.
2. Tie load to the frame of equipment or use tag lines.
3. Keep travel speed to a minimum.
4. Use a dedicated spotter for all equipment movements.
5.2.4 Weight of the load must be positively established prior to handling. Check
brakes and machine stability when load is still only inches above the
ground.
5.2.5 All crawler type equipment shall not be moved unless a designated signal
person is in full view of the operator giving signals.
5.2.6 Whenever internal combustion engine powered equipment exhausts into
an enclosed space, air monitoring shall be conducted and recorded to
verify that employees are not exposed to unsafe concentrations of toxic
gases or oxygen deficient atmospheres.
5.2.7 A firm, drained, and level foundation capable of supporting the load shall
be provided. Mats or other cribbing shall be used at all times to meet the
manufacturer’s specification for adequate support and degree of level of
the equipment used.
5.2.8 A competent and qualified person must direct the assembly/disassembly of
all cranes and associated equipment.
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5.3 Crane and Lifting Equipment Work Near Overhead Power Lines
5.3.1 If a crane or lifting equipment is operated near power lines, follow
Table A of the OSHA Construction Table, which has minimum distance
based on voltage.
TABLE A—MINIMUM CLEARANCE DISTANCES
Voltage
(nominal, kV, alternating current)
Minimum clearance distance
(feet)
up to 50
over 50 to 200
over 200 to 350
over 350 to 500
over 500 to 750
over 750 to 1,000
over 1,000
10
15
20
25
35
45
(As established by the utility owner/operator or
registered professional engineer who is a qualified
person with respect to electrical power
transmission and distribution).
Note: The value that follows "to" is up to and includes that value. For example, over 50 to
200 means up to and including 200k
5.3.2 The power company should be asked if it is possible to de-energize the
power line or install temporary sleeves and visibly verify that the power
line has been grounded at the worksite.
5.3.3 All overhead lines are considered energized unless disconnected and
physically grounded.
5.3.4 If the line is not de-energized, the employer must:
1. Conduct a meeting, with the crew to review measures to
prevent encroachment.
2. Conduct a pre-operation hazard assessment to identify the
work zone and determine if any part of the equipment/load
will be within the minimum clearance distance.
3. Use only nonconductive tag lines.
4. Warning flags or other suitable devices may be positioned to
define the allowable operating zone of the personnel or
equipment.
5. Use a dedicated spotter, a proximity alarm, a range control
warning device, an automatic limit device or an elevated
warning line/barrier in view of the operator.
5.3.5 No part of the crane or lifting equipment, including the load, may be
allowed to get closer to bare live circuits or apparatus than the spacing
indicated in Table A.
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5.4 Overhead Cranes (RESERVED)
5.5 Hand Signals
5.5.1 A signal person is required when:
1. The point of operation is not in full view of the operator.
2. The operator’s view is obstructed in the direction the equipment is
traveling.
3. Either the operator or the person handling the load determines that a
signal person is needed because of site-specific safety concerns.
5.5.2 Any person giving hand signals or verbal signals to an operator shall be
qualified by one of the following two methods:
1. Third party qualified evaluator. The signal person has documentation
from a third party qualified evaluator showing that he or she meets the
qualification requirements.
2. Employer’s qualified evaluator (not a third party). The employer’s
qualified evaluator assesses the individual, determines the individual
meets the qualification requirements, and provides documentation of
that determination. This assessment may not be relied on by other
employers.
5.5.3 It is important that the operator, signalperson, and crew receiving the load
work together as a team. The operator must pay close attention to the
directions given by the signalperson.
5.5.4 Quick and understandable communication between the signalperson and
the operator is required for safe and efficient operation.
5.5.5 Both the operator and the signal-person shall know standard hand signals.
If other communication methods are necessary for a job, both persons
should agree on them and their meanings.
5.5.6 Operator and signal-person may require the use of radios to communicate
when the visibility between the operator and signalperson becomes
limited.
5.5.7 OSHA 1926.1422 requires that a hand signal chart must be posted on the
crane or conspicuously in the vicinity of the hoisting operations.
5.6 Inspection of Cranes and Lifting Equipment
5.6.1 A competent person shall be designated to inspect all cranes and lifting
equipment prior to each use to be sure that it is in safe operating condition.
Any defective safety device or equipment MUST be repaired by a
competent person before continued use. A record of the results of this
inspection will be maintained by the contractor operating the equipment
and must be on record at the project. Frequent inspections (Daily) shall be
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made utilizing manufacturer’s recommendations and shall include the
following:
a. All control mechanisms for maladjustment interfering with
proper operation.
b. All control mechanisms for excessive wear components
and contamination by lubricants or other foreign matter.
c. All safety devices including but not limited to boom angle
indicators, boom stops, boom kick out devices, anti-two
block devices, and load moment indicators where required.
d. Deterioration or leakage in air or hydraulic systems.
e. Lifting hooks with deformations or cracks.
f. Hooks with cracks or having more than 15 percent in
excess of normal throat opening.
g. More than 10 degree twist from the plane of the unbent
hook.
h. Rope reeving for noncompliance with manufacturer’s
recommendations.
6.0 Annual Crane Inspections
6.1 A thorough, annual inspection of all cranes will be made by a competent person
certified for inspection. A record of the date and result of this inspection must be
maintained in job site records and available for review upon request. Periodic
inspections (Annual) shall include the items listed for frequent inspection plus the
following:
1. Deformed, cracked, or corroded members in the crane structure
and boom.
2. Loose bolts or rivets.
3. Cracked or worn sheaves and drums.
4. Worn, cracked, or distorted parts such as pins, bearings, shafts,
gears, rollers and locking devices.
5. Excessive wear on brake and clutch system parts, linings, pawls,
and ratchets.
6. Load, boom angle, and other indicators over their full range, for
any significant inaccuracies.
7. Gasoline, diesel, electric, or other power plants for improper
performance or noncompliance with safety requirements.
8. Excessive wear of chain-drive sprockets and excessive chain
stretch.
9. Travel, steering, braking, and locking devices.
10. Excessively worn damaged tires.
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6.2 A crane which has been idle for a period of one month or more, but less than 6
months, shall be given an inspection conforming to requirements of a frequent
inspection and examination of all ropes and cables (hoisting equipment). Cranes that
have been idle for longer than 6 months must have the periodic inspection (annual
inspection).
6.3 Certification records which include the date of inspection, the signature of the person
who performed the inspection and the serial number, or other identifier, of the crane
which was inspected shall be made monthly on critical items in use such as brakes,
crane hooks, and ropes. This certification record shall be kept readily available.
6.4 Cranes used in marine applications require annual certification by a government-
licensed inspector.
6.5 Load lines should be checked routinely and thoroughly:
1. In the running line, if there are six randomly distributed broken
wires on one lay or three broken wires in any one strand in one lay,
the line should be taken out of service.
2. If there is wear of one-third of the original diameter, kinks,
crushing, bird-caging, or any other distortion of the rope structure,
the rope should be taken out of service.
6.6 Rated load tests - Written reports showing test procedures and confirming the
adequacy of any repairs or alterations shall be kept and maintained in the jobsite
records.
6.7 Test loads shall not exceed 110 percent of the rated load at any selected working
radius.
6.8 In addition to prototype tests and quality-control measures, each new production
crane shall be tested by the manufacturer to the extent necessary to insure
compliance with the operational requirements including functions such as the
following:
a. Load hoisting and lowering mechanisms
b. Boom hoisting and lower mechanisms
c. Swinging mechanism
d. Travel mechanism
e. Safety devices
6.9 Where the complete production crane is not supplied by the manufacturer such tests
shall be conducted at final assembly.
6.10 Certified production - crane test results shall be made available.
6.11 No cranes shall be re-rated in excess of the original load ratings unless such rating
changes are approved by the crane manufacturer or final assembler.
6.12 No modifications or additions which affect the capacity or safe operation of the
equipment shall be made by the employer without the manufacturer's written
approval. If such modifications or changes are made, the capacity, operation, and
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maintenance instruction plates, tags, or decals, shall be changed accordingly. In no
case shall the original safety factor of the equipment be reduced.
6.13 All crawler, truck, or locomotive cranes in use shall meet the applicable
requirements for design, inspection, construction, testing, maintenance and operation
as prescribed in the ANSI B30.5-2014 Safety Code for Crawler, Locomotive and
Truck Cranes.
6.14 The written, dated, and signed inspection reports and records of the monthly
inspection of critical items prescribed in section 5-2.1.5 of the ANSI B30.5-2014
standard are not required. Instead, the employer shall prepare a certification record
which includes the date the crane items were inspected; the signature of the person
who inspected the crane items; and a serial number, or other identifier, for the crane
inspected. The most recent certification record shall be maintained on file until a
new one is prepared.
7.0 Routine Lifts
7.1 Routine lifting operations may be executed under a basic lift plan which can be
outlined on the JSA. The lift plan must clearly define the following:
a. limitations of the lifting equipment
b. load size
c. weather conditions
d. signaling methods
e. rigging
f. lifting methods
g. areas of operation
h. overhead obstructions
i. person responsible for the lift
7.2 All personnel involved in the lift shall review the lift plan prior to the lift.
7.3 The following are considered routine lifts:
a. Lifting over non-sensitive areas
b. Suitable environmental conditions
c. Load has known and evaluated weight, shape and center of gravity
d. Standard rigging arrangements
e. Load under 75% of rated load of the load chart
f. Use of a certified lifting point
g. Acceptable clearance to overhead obstructions
h. Single lifting machine
8.0 Critical lifts
8.1 Critical lifting operations will require a more detailed lifting plan utilizing Form A.
The plan must be reviewed by the crane operator, lift supervisor, the Buckeye PIC,
project manager, and local HSSE prior to commencement of any critical lift. Any
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deviation requirement identified from the plan, must follow Buckeye’s standard
deviation process prior to commencement of the lifting operation.
8.2 A Critical Lift is a lift which includes any of the following factors:
a. Use of two or more lifting apparatus – tandem lifts
b. Lifting over live piping or occupied buildings
c. Lifting of machinery without lifting points
d. Lifting personnel in work baskets
e. In environmental conditions likely to affect equipment
performance
f. Load with unknown / difficult to estimate weight and/or center of
gravity
g. Non-standard rigging arrangements
h. Load lowered into or lifted from a confined space
i. Weight of load in excess of 75% rated load of the load chart
j. Dangerous cargo lifts i.e. risk of fire or explosion or cargo with
significant health hazard risks
k. Lift within the clearance zone limitations noted in Table A
8.3 Critical lift plan
8.3.1 A critical lift plan, with documentation as determined by site supervision
or project management, shall be prepared on all critical lifts prior to the
commencement of those lifts.
8.3.2 The critical lift plan shall include items necessary to address the special
conditions of each lift. These items should include, but not be limited to:
1. The total weight to be lifted, which includes, but is not
limited to the weights of:
a. Load
b. block and ball
c. below-the-hook lifting devices, lifting bars, or
beams
d. jib, erected or stowed, as applicable
e. rigging, including slings and hardware
f. rope, load line as applicable
2. The crane or lifting equipment placement location with
consideration given to:
a. foundation, ground support
b. boom swing area, as applicable
c. track or outrigger loading
d. electrical hazards
e. obstructions and clearances
f. load path
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3. Identification of the crane(s) or lifting equipment to be used
describing the required configuration(s) noting:
a. capacity
b. lifting arrangement
c. load radius requirements
d. percentage of crane capacity needed
e. load chart
4. Sling and rigging selection, which should include, but not be
limited to:
a. type of arrangement
b. identified sling angles
c. number and size of slings
d. sling rated capacities and lengths
e. hardware selection and sizing
5. Diagram of lifting area dimensions including:
a. site layout information and rigging arrangements
b. pick up and placement locations
c. obstructions and clearances
d. jobsite access and egress for the load
e. load orientation
f. outrigger locations and support
6. Diagram of rigging configuration including
a. arrangement of slings and below-the-hook lifting
devices
b. hardware arrangements
c. capacities of slings and hardware
d. pick points on the load
e. calculated sling angles
f. types of sling hitches
7. Sequence of lift and lift execution including:
a. Communication plan
b. Names of personnel for required positions
c. Name of qualified operator
d. Name of lift supervisor
e. Names of reviewers
f. Name of spotter
g. Name of signal person
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8.3.3 Critical lift approvals
8.3.3.1 All critical lift plans shall be reviewed signed, and dated by
responsible jobsite personnel including onsite management,
rigging supervision, the crane or equipment operator performing
the lift, qualified personnel designing the lift, and safety personnel
noted on the critical lift template.
8.3.3.2 The crane or equipment operator and lift supervisor shall sign as
approvers of the critical lift.
8.3.3.3 Any disapproval(s) or disagreement by the responsible personnel
shall cause the plan to be re-examined and, if necessary, revised to
gain final approval. All revisions shall be signed and dated.
8.3.4 Critical lift pre-lift meeting
8.3.4.1 Before performing a critical lift and following any revision(s) to
the original plan, participating personnel shall meet to accomplish
the following:
a. Review and discuss the details of the critical lift plan
b. Discuss any hazards, delays, project coordination, unique
conditions, emergency contingencies, safety concerns, etc.
c. Resolve any questions or concerns before commencing
lifting operations
d. Assign personnel and responsibilities
e. Establish communication methods
9.0 Rigging
9.1 Qualified riggers must be used for crane activities during assembly and disassembly
work.
9.2 Qualified riggers are required whenever workers are within the fall zone and
hooking, unhooking, or guiding a load, or doing initial connection of a load to a
component or structure.
9.3 A qualified rigger is a rigger who possesses a recognized degree, certificate or
professional standing or has extensive knowledge, training and experience. Must
also be able to demonstrate the ability to solve problems related to rigging loads.
9.4 Careful selection of quality rigging material is important. Rigging material shall be
only procured from a known and reliable supplier of dependable rigging materials
9.5 Only approved slings and rigging will be used as lifting devices. Devices such as
“come alongs”, which are designed for pulling and have a quick release for binding,
cannot be used for lifting.
9.6 All slings (chain, wire rope or synthetic) shall have a tag affixed that clearly
indicates the lifting capacity. The tag must be legible and displays the load capacity
for a straight hitch, basket hitch, or choker hitch. Do not load lifting devices and
slings beyond their rated working capacity.
9.7 All lifting equipment and slings must be visually inspected for defects before each
use. Do not use items found to be defective. Each sling must have a thorough and
documented periodic inspection not to exceed 12 months conducted by a competent
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person. Slings found to be defective cannot be repaired and must be destroyed and
discarded.
9.8 Initial manufacturer certification for new slings and other rigging equipment to
include spreader bars and personnel baskets, along with subsequent documented
inspections must be retained for the life of the sling. All documentation noted above
will be maintained and retained by the owner of the sling. Documentation shall be
available upon request.
10.0 Hoists
10.1 Electric and Air-powered Hoisting Equipment
10.1.1 Powered hoisting equipment comes in several types and includes electric-
powered and air powered. In all cases, the following controls shall be
applied:
1. The operator shall test all controls before beginning a lift.
2. If any controls do not operate properly, the operator shall adjust,
repair, or tag out the hoist as necessary.
3. Before operating the hoist, the operator shall make sure hands are
clear from all moving parts.
4. The operator shall test the brakes when a load is first being
handled by raising the load just enough to clear the floor, or
supports, and checking for brake action.
5. The lift should be continued only after the operator ensures that
the braking-system is operating properly.
6. The upper limit device shall not be used as a normal operating
control.
7. Air hoists shall be connected to an air supply of sufficient capacity
and pressure to safely operate the hoist.
8. The operator shall verify that all air supply hoses are positively
connected to prevent disconnection during use.
9. Hooks shall have spring-loaded latches.
10.2 Manually Operated Hoisting Equipment 10.2.1 Manually operated hoisting equipment comes in several types and includes
ratchet style and manual-chain blocks. In all cases, the following controls shall be
applied:
1. The operator shall maintain control of the hoist lever until the ratchet
pawl is engaged and the lever is at rest.
2. Application of a means of power, other than hand power to operate
manually operated hoists is prohibited.
3. The use of an extension such as a cheater bar is prohibited.
4. Hooks shall have spring-loaded latches.
10.3 Inspection and Testing hoists 10.3.1 Inspections of hoists are mandatory and shall conducted:
a. Before being used for the first time
b. Prior to each use
c. Annually with a documented inspection
d. After substantial alteration or repair - requires testing and documentation
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10.3.2 Annual inspections and substantial repairs or alterations shall be conducted
by a qualified third party.
11.0 Jacks and Air Bags 11.1 The manufacturer’s rated capacity shall be legible on all jacks and air bags. Ensure
that the jack or air bag selected has the rating sufficient to lift and sustain the load.
11.2 Jacks and airbags shall be inspected before each use, Refer to the manufacturer’s
recommendations for additional inspection requirements.
11.3 Refer to manufacturer’s recommendations for air pressure limitations.
11.4 After a load has been raised, crib, block, or otherwise secure the load. Relieve the
load on the jack or air bag slowly releasing the internal pressure until the load has
been transferred to the permanent support.
11.5 Air bags must not be stacked more than two high.
References
Procedure Title/Source Procedure Identification
American National Standards
Institute (ANSI)
ANSI B30.5-2014
29 CFR 1926.1400