Crane Safety Precautions

Crane Safety Precautions

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PurposeThis procedure and practice is provided as a guide to Contractor, its subcontractors their staff, and specifically the rigging staff and rigging coordinators to execute all crane lifts safely. This procedure shall be implemented by Contractor and enforced by Owner on the Project.

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SCOPE

This procedure provides the following:Establishes the requirement for organizing a Contractor Crane and Rigging Group, lists personnel and defines their role in the successful execution of this practice, identifies the responsibilities of key personnel for this practice.Identifies the requirements for design and review of lifting lugs. Categorizes rigging lifts for and establishes responsibility for the design, engineering and approval of the transportation and rigging of all equipment and modules. This practice covers all crawler cranes, truck cranes, carry deck cranes, monorails, boom trucks, etc. Establishes guidelines that must be adhered to when requiring a variance from this procedure.

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Crane Operator A qualified person who is licensed, trained, certified and experienced in the use, the capabilities, and all of the functions of a specific machine, mechanical system, or tool. All Crane Operators must meet the following requirements:An up-to-date shall be on file with Contractor, detailing specific experience in crane operation.

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SignalmanA designated person who is trained and experience in hand signals used and understood by crane operators. One designated signalman will be responsible for the control and coordination of any particular lift or Heavy Rigging Activity and shall wear a green reflective vest. Under certain conditions, such as multiple crane lifts, or lifting "in the blind", it may be deemed necessary for additional signalmen to participate in a lift or Heavy Rigging Activity. One signalman will be designated as the Lead Signalman.

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ResponsibilitiesResponsible Personnel - The crane operator, and the qualified field rigger, are jointly responsible for determination of the load weight and placement of the crane so that it is set up within the operating radius selected. The rigging supervisor has final responsibility for all operations.

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ContentsCranes Instructions & StandardsCranes Components & Stability Operations Responsibility Maintenance or Construction ResponsibilityCritical LiftsPrecautionsIncidents

SAFETY

I THINK SAFE

I KNOW THE RULESI ACT SAFE

I FOLLOW THE RULESIf YOU THINK SAFE..and YOU ACT SAFE -

YOULL BE SAFE

Lets take a look at, and understand Stability

Most of crane incidents within the company are due to loss of stability

STABILITY 1.1 Outrigger spans1.2 Outrigger set-up1.3 Counterweight options1.4 Center-of-gravity1.5 Tipping axis

OUTRIGGER SPANS

Partial extensionFull extension IT IS NOT ALLOWED TO MIX SPANS-

ONLY ALL FULL SPANS MAY BE USEDORONLY ALL PARTIAL SPANS MAY BE USED

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CORRECT OUTRIGGER SPAN 1

ALL MAXIMUM SPAN

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CORRECT OUTRIGGER SPAN 2

ALL PARTIAL SPAN

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INCORRECT OUTRIGGER SPAN 1

XPARTIAL SPANFULL SPAN

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INCORRECT OUTRIGGER SPAN 2

XFULL SPAN

PARTIAL SPAN

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THE BEAMS TRANSFER LOAD TO THE CARRIER AT THE CORRECT POSITIONS WHEN CARRIER WHEELS CLEAR THE GROUND.SPAN OPERATION

CRANE (AND LOAD) WEIGHT

THIS BEAM TRANSFERS LOAD TO THE CARRIER AT AN INCORRECT POSITION WHEN CARRIER RAISES.

THIS AREA IS NOT STRONG

INCORRECT SPAN - OPERATOR ERROR

X

OPERATOR ERROR

This accident is due to an Operator Error.He used an Incorrect Outrigger Span..!No extension beams used

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OUTRIGGER SECURITY

FOR ROAD TRAVEL, THESE LOCKING DEVICES MUST BE USED

X

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TIPPING AXIS EXPLANATION 1

TO RIGHT SIDEoutriggers nearest to the load

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TIPPING AXIS EXPLANATION 2

STILL TO RIGHT SIDE

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CRANE LEVERAGE ABOUT THE TIPPING AXIS

CRANE WEIGHTTIPPING AXIS

LOAD WEIGHT

outriggers nearest to the load

XY

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OPERATOR ERRORThis accident is due to an Operator Error. He moved the crane Center-of-Gravity outside the crane Tipping Axis.

Crane was on tires only. No outriggers in use

Outriggers

Lift Configuration

Boom

Counterweight

Parts-of-Line

Operating Code LIFT CONFIGURATION

Lift Configuration

Lift Configuration

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OPERATOR ERROR

INCORRECT CONFIGURATION

CRANE INSPECTIONI must ensurethis machine is safe to useIf it is to be used for travelingIf it is to be used for craning

Even for a run-up,an inspection is needed

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Operation Responsibility

Crane, Crane Operator, Rigger Certificate. Maintain daily checklistAn approved lift plan provided. Heavy lifts must be noted on the Work Permit.If load critical or man basket required operation foreman should issue the work permit. Crane location and positioning.Critical Wind Speed. Stop the work

Obtaining a work permits from the operating Unit Foreman before bringing the crane inside the operating area.Ensure that the crane is in good operating condition.Strictly adhere to the procedures and precautions mentioned in WP.Immediately stop work if unsafe conditions or crane incident and immediately report.Ensuring that an approved Lift Plan is utilized if the lift has been determined to be a Critical Lift"..

Maint. / Construction Responsibility

Critical Lift Critical lifts are defined as high risk lifts where there is a potential for serious injury, major property loss, or disruption of programs or projects. The following are examples of the critical lifts:1. Around energized electrical lines.2. Near or over hydrocarbon loading piers.3. On barges, vessels and hydrocarbon loading piers.4. Around and over populated/traffic areas.5. Tandem, multiple or tailing lifts.6. On rubber or pick and carry lifts.7. Personnel Platforms (man lifts)8. High level or long reach lifts.

SAFETY PRECAUTIONSCrane & accessories shall be kept in good condition.The crane shall have a sticker updated every three months Crane operated in the vicinity of spills or leaks, special precautions must be undertaken.The weight of the crane shall be stenciled on the crane.Repair work, maintenance or refueling inside the Unit battery limits.Moving of a crane into or out of an operating unit.The traveling of cranes with suspended loads is not allowed in Rabigh Refinery

XXPoor flat support

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XXX

Load is too close from the crane

Telescoping out and increasingThe load radiusToo much load

Strength structure failure

Stability Tripping failure

RESULT

Incidents

1/12/2015QJF34Be familiar with your SAFETY reference before it could happened

Crane Incident

This accident is due to an Operator Error. The operator programmed the incorrect code into the R.C.L. or it was by-passed and then he moved the crane Center-of-Gravity outside the crane Tipping Axis.

Crane Incident

10.5t Counterweights

Stabilizers are retracted

1/12/2015QJF36On March 16, 2006 at 1645 hours, a crane near miss incident took place on the access road to the Platformer unit while exiting from the area.There were no injuries to personnel or damages to the Refinery properties. The crane sustained partial damage. The initial findings of the incident appear to be that while the crane was moving stuck in the storm water drainage open ditch and crane turn over during maneuvering. This incident is being investigated by Road & Heavy Equipment Department with representatives from Riyadh Refinery, Loss Prevention and Inspection Department. In addition, RRD is currently investigating this near miss incident in relation to the Refinery part to identify root causes and lessons learned. You will be updated of committee findings.

Crane Incident

Note the trench here

The crane was on tires with wheels in the trench.If the operator had knowledge of drive modes, this accident would not have occurred

Crane Incident...TIPPING (OR OVERTURNING) OCCURSIts as simple as that!!!This accident is due to an Operator Error. The operator programmed the incorrect code into the R.C.L. or it was by-passed and then he moved the crane Center-of-Gravity outside the crane Tipping Axis. (Rigger was not attend)

RiggingAll manufactured rigging equipment including, but not limited to: slings (nylon and wire),chokers, wirerope lashing, come-alongs, chain falls, etc.Contractor shall ensure all rigging equipment shall be free from defects, in good operatingcondition and maintained in a safe condition and shall bear the serial number of themanufacturer and the Safe Working (SWL) Load capacity marked on it. All rigging equipmentwill also be accompanied by the manufacturers certificate indicating the serial number andcapacity.

Safe Work Practices

1. Rigging and lashing should be protected from damage by softeners or other activemeans while in place.2. Nylon, rope, or other slings subject to damage by sharp edges shall be protected duringthe lift.3. The chains or ropes of a come-along or chain fall shall not be used as chokers.4. Lifting bays used to make lifts will be barricaded at ground level to protect employeesfrom walking under loads.5. Buckets, barrels, tubs, etc. used to lift smaller objects shall be effectively covered andsecured during lifting to prevent accidental spillage of their contents.6. Sheet metal, boiler siding, insulation or other objects of a sheet nature will not be liftedby sheet dogs without the prior approval of the Project Manager.7. Rigging equipment will not remain in the elements longer than necessary to do thework, protected from mud, dirt and chemical exposures.8. No hand spliced slings are allowed on the project.9. Nylon slings are not allowed for hoisting structural steel.10. Single sling lifts are not allowed.11. Only inspected rigging equipment bearing the colour coding for the month and thathave the SWL indicated on it and with the manufacturers certification shall be allowedto be used.

InspectionInspectionAll rigging will be inspected on a monthly basis. The inspection will be conducted and documented. Inspection reports are to turned in to the Project Safety Office, by the fifth (5th) day of that month. The Rigging Supervisor, or his designee will conduct this inspection.Contractor shall make the inspection records and manufactures certifications and specifications of the rigging equipment available to OWNER upon request. The Rigging Supervisor or designee will insure that any item found to be defective is removed from service immediately. These items, if found to be unacceptable, will be tagged out of service, "DO NOT USE," and returned to the tool room/warehouse.All rigging equipment found to be in good condition when inspected shall be color coded for the monthly period, and valid for that period only.

Color CodingThe color coding scheme and placement of color coding for rigging equipment on this projectwill be as follows:-Yellow Blue Orange Green Red WhiteJanuary February March April May JuneJuly August September October November DecemberNOTE!!! Colour coded tie-wraps may be substituted for tape.

EQUIPMENT REQUIREMENTS

All motorized equipment must have a reverse signal alarm audible at 30 meter distance above the surrounding noise level. In addition while the equipment is being operated shall have a flagman wearing a yellow reflective vest and equipped with a red flag and a green flag.All cracked and broken glass shall be replaced before bringing vehicles on the jobsite. If glass is broken or damaged on jobsite and if damage is severe enough to cause a potential safety problem, the machine shall be stopped until such damage has been repaired.Vehicles used to transport employees shall have seats firmly secured and adequate for the number of employees to be carried and all passengers should be properly seated. Standing on the back of moving vehicles is prohibited. It is not allowed to transport employees in the back of pick-up trucks or any open vehicle.

EQUIPMENT REQUIREMENTS

Owner shall review and approve locations for storage of all fuels, lubricants, starting fluids prior to use by Contractor for storage.Contractor shall equip all vehicles and fuel driven construction equipment with a fire extinguisher, red triangles, flashlight and a first aid kit.Safety DevicesContractor shall equip all vehicles and fuel driven construction equipment with a fire extinguisher, red triangles, flashlight and a first aid kit.All rubber tired, self propelled scrapers, rubber tired, front-end loaders, rubber tired dozers, wheel type agricultural and industrial tractors, crawler tractors, crawler type loaders and motor graders shall be equipped with rollover protective structures and seat belts.Inspection of these devices will be included as part of the operators' daily pre-operational inspection, as well in the formal monthly inspection.No equipment shall be operated with defective or missing safety devices.

Engineered LiftsEngineered lifts are categorized A , B and C lifts.A LiftsLifts up to one hundred (100) tons per the following requirements:VesselsVertical30 tons and over Vertical2.4 meters (8 feet) diameter and overHorizontal60 tons and overAll other equipment and structures sixty (60) tons and over.Equipment or vessels over twenty (20) tons that are inside structures, in inaccessible locations, over operating processes or in hazardous areas as determined by the site manager or rigging engineer. Also included is equipment and vessels constructed of nonferrous materials, or are otherwise prone to damage during handling.All multiple crane lifts (exclusive of a tailing crane) in which the load could be transferred from one crane to another during the lift.All lifts over eighty (80) percent of the capacity chart of the crane for the boom length and operating radius being used, or over ninety (90) percent if the crane has an operational load indication device with an overload cut-off.Transportation - All plant equipment over sixty (60) tons.

B Lifts Lifts 100 to 600 tons.Responsible personnel for a Type B engineered lift must be:C Lifts Lifts six hundred (600) tons and above.Prior to awarding a rigging contract and approving a rigging plan, the manager of the project along with the site manager and rigging manager shall review the rigging plan, risk analysis, and/or contractor bid evaluation to ensure that risk/liabilities are understood and mitigated to the maximum extent possible.

SUMMARY

This specification describes the requirements for furnishing all engineering, supervision, labor, equipment, tools, materials, services, and supplies necessary to provide transportation, erection, and material handling services to satisfy the particular requirements of the project/site. This specification provides these requirements for services performed by Contractor.