crane safety and awareness presentation

8/18/2019 crane safety and awareness presentation

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Crane Safety and

Awareness


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WPS Lifting Equipment Pull TestingPolicies and Procedures

• For safety reasons our customers are requiring stricter controlof lifting equipment certifications. As a company Halliburtonstresses safety as a daily practice.

• There are many types of equipment that will fall under thecategory of “Lifting Equipment” in our operations. Listed beloware examples:

• Rig Up Equipment• Lifting Slings• Tool Lifting Caps

• Anything that is used as lifting equipment, used in lifting, orthat is lifted must be certified


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Definition of Terms

• Maximum Working Tension: the maximum recommendedtension load applied on the wireline cable. The vendor’spublished information points us to 50% of the breakingstrength of a new line as the best general guideline for safe

pull on a cable.• Working Load: the maximum allowable tension load that canbe placed on a piece of equipment.

• Hook Load: the load seen on the upstream side of a pulleyassembly. In our case it refers to the load above the topsheave; twice that of the cable pull, as it crosses the sheavewheel.


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Definition of Terms

• Proof Load: the amount of tension that is to be applied to theLifting Equipment, in test to re-certify it for another year ofservice. The Proof Load is higher than the working load toallow for the dynamic nature (rapidly changing or shock) of theloads seen in actual operations versus the static nature of theProof Load testing.

• Safety Factor: the Proof Load / Working Load. For overheadlifting equipment, this is a 4:1 factor.


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Definition of Terms

• Visual Inspection: lifting equipment should be visuallyinspected any time it is used. It is recommended that this also

be performed on a monthly basis for seldom used equipmentand is mandatory during annual recertification.

Visual inspection should include the inspection of thelabeling to ensure it is still within certification and thecertification and ratings are still legible on the tag.


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Load Testing

•It is the responsibility of the field operations location to re-certify lifting equipment on an annual basis.

• Re-certification must include a Proof Test, mechanicalinspection of assemblies for wear or corrosion, and testdocumentation (certificate & tagging). Lifting equipmentassemblies shall be tested up to but not exceeding their ProofLoad.

• It is required that a non-destructive material testing (dyepenetrate or magnetic particle / MPI) be completed on all castcomponents of the assemblies to check for cracks orinclusions.


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Load Test Color Coding

•Color coding is mandatory for any equipment that has beenannually certified.

• Halliburton’s color coding system will not override a customercolor code requirement. If any customer requires a color codefor annual certification identification their color code will takeprecedence over the Halliburton color code.

• The main purpose of color coding is to make it easy to identifywhether a lifting device or lifting point is within requirements.The colors selected should be easy to see day or night, andshould be visible for an operator of a crane or fork lift.



Load Test Color CodingWPS Color Sequence for Annual Certification of Lifting Equipment

1. The valid color code shall only be applied after satisfactory results of an inspection.2. Other ways of color coding other than painting such as plastic, tags, etc. may be

required for polyester slings, items that get heavy use, etc.3. Anything with an inspection interval different than one year should be identified

accordingly.4. Customer Color Code requirements will take precedence over the Halliburton color

code.5. Red Color Code will be used for equipment that is not fit for service.

Light Blue FluorescentOrange

OrBright Orange

FluorescentGreen

OrBright Green

FluorescentYellow

OrBright Yellow

1 st Half Even Yearsi.e. Jan – June 00,02, 04, 06, 08

2 n Half Even Yearsi.e. July – Dec 00,02, 04, 06, 08

1 st Half Odd Yearsi.e. Jan – June 01,03, 05, 07, 09

2 n Half Odd Yearsi.e. July – Dec 01,03, 05, 07, 09

Red is forEquipment

that is Not Fitfor Service



What Color would I use to identify a piece of LiftingHardware that was Tested on December 3, 2010?

1 2 3 4

0 00

11. Fluorescent Yellow2. Light Blue

3. Fluorescent Orange4. Fluorescent Green



Hooks

Hooks MUST have a Safety Latch or Clip.This Prevents the Hook from Twisting out

of the Device it is Attached to.

If a Hook does not have a Safety Clip, or the Clipis Broken, DO NOT USE IT. Replace the Hook

or Have the Safety Clip Repaired



Visual Inspection of hooks



Visual Inspection of Hooks



Inspection of Shackles

Do not use Shackles that don’t have Bolt \ Nut \ Safety Pin!Only use Approved Shackles



Tool Lifting Handcuffs

“This is the only Approved tool lifting chain device”OEB 2002/058

http://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/FieldNotification_OEB-2002_058_1%20(Only%20Approved%20Open%20Hole%20Tool%20Handcuffs)%20.dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/FieldNotification_OEB-2002_058_1%20(Only%20Approved%20Open%20Hole%20Tool%20Handcuffs)%20.doc



Wire Rope Clips

“Never Saddle a Dead Horse”

Saddle on Live orLoad side of Line U-Bolt on

Dead orUnloaded sideof the line



Rig Up Equipment

Do not use Wire Rope Slings to tie off Sheave Wheels!Only use Certified Load Tested Chains

http://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdf

http://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdfhttp://halworld.corp.halliburton.com/internal/hms/wps/pubsdata/ST-GL-HAL-WPS-421.pdf



Hand Tools

Break Over Style Chain Binders are not Recommended



Load Test Rating Tags

Make sure all chains, slings, clevises, sheave hangers, and

anything involved in wireline rig up has a load test ratingcertification tag that is legible.

DO NOT USE ANY EQUIPMENT THAT IS NOT LEGIBLY TAGGED!



Sheaves

Sheave WheelsCome in various diameters to Match different cablesInspected, Load Tested & Certified Annually



Sheaves

OEB - 2009/021

http://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_021_1%20(30%20inch%20Sheave%20Guard).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_021_1%20(30%20inch%20Sheave%20Guard).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_021_1%20(30%20inch%20Sheave%20Guard).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_021_1%20(30%20inch%20Sheave%20Guard).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_021_1%20(30%20inch%20Sheave%20Guard).doc



Sheave Wheel Hand Guard

OEB-2009/082

http://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_082_1(Sheave%20Wheel%20Hand%20Guards).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_082_1(Sheave%20Wheel%20Hand%20Guards).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_082_1(Sheave%20Wheel%20Hand%20Guards).dochttp://localhost/var/www/apps/conversion/tmp/Rig%20Up%20Equipment/~$eldNotification_OEB-2009_082_1(Sheave%20Wheel%20Hand%20Guards).doc



Sheave Wheels

Groove too narrowPinches cable

Correct groove

Cable well supported

Groove too wideCable squashed



Tool Lifting Caps

• All lifting caps must be certified annually with a proof test of10,000lbs and a dye penetrant inspection on each cap. Totrack the testing all caps must be serialized in each location.


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Tool Lifting Caps


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Pressure Gear Lifting Caps• The recommended lifting devices for pressure control

equipment include lifting clamps, spreader bars, lifting capsand slings of the proper size for the rig up hardware beinghoisted.

Clamps and Spreader Bars are used to rig up lubricators on thewell site.Lifting Caps are used to move and rig up BOP and heavy crossover adapters.

All of these items must be certified and have original manufacturingand testing documentation on file. This equipment mustsuccessfully undergo a proof load test of 2 times the working loadrating prior to first entering service and must be subjected to visual

inspections before each use and annual certification to remain inservice. All lifting equipment must be clearly marked with apermanent serialized part number and identified with the WorkingLoad Limit rating.


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Pressure Gear Lifting Caps

ll Skid d


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Boxes, Pallets, Skid Pad EyeInspection Criteria

• Inspect pad eye on offshore boxes, containers, pallets, skidsfor the following:

Check the tag for certification and load ratingWear Nicks, Cracks, GougesModifications

B P ll t Skid P d E


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• All lifting containers must have the following:Be permanently marked with the maximum load capacity.Have clearly identified lifting points capable of handling the totalcapacity of the load.Have machined pad eye or lifting points (not flame cut).Have undamaged lifting points or pad eyes.

All pad eyes should be visually inspected before every use. Inaddition, all pad eyes require and annual certification. Annual

certification includes a visual inspection, a load certification and anMPI or dye penetrant.Each lifting point must carry the current corresponding color code.

B P ll t Skid P d E


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• Lifting Container lift test procedure: A visual inspection will be carried out on the pad eyes and thecontainer being tested.Container shall be loaded to a total weight of the maximum loadcapacity rating of the container and lifted using all the pad eyes.Test load should be evenly distributed inside the container.Container shall be lifted by a standard lifting set and should beheld, clear of the ground, throughout the test.The force should be applied using calibrated weights and lifting thecontainer by means of a suitable test rig or crane.

The date of inspection should be indicated on the container(preferably on a plate fitted specifically for this purpose).


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Synthetic Sling Inspection Criteria

• Inspect synthetic slings for the following:Check the tag for certification and load rating Acid or Caustic BurnsMelting or CharringHoles, Cuts, Punctures, Crushed FabricTears, SnagsBroken StitchesWorn StitchesExcessive Abrasion or Wear on webbing or fittingsKnots

Discoloration Anything that causes doubt to the continued use of the sling


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Synthetic Sling Inspection Criteria

• Additional requirements for synthetic web slings include:Each sling must be clearly marked to show the rated capacities foreach type of hitch, web material and manufacturer.Slings must contain web that is of uniform thickness and width, andthe edges must not be split from the webbing width and must not

be unraveling.Fittings must be free of all sharp edges that could damage thewebbing and must me of a minimum breaking strength equal to thatof the sling.Stitching shall be the only method used to attach end fittings towebbing and to form eyes.Nylon and polyester slings must not be used at temperatures above200 deg F.


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Steel Chain Inspection Criteria

Bent LinksCracks in Welded Areas, Shoulders, or any other sectionof the link.

Excess wear in the Bearing Surface of the Link.Transverse Nicks and Gouges.Corrosion PitsStretching Caused by Overloading.

Increase in reach of the Sling as compared to itsOriginal Length


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Wire Rope Slings

• Inspect wire rope slings for the following:Check the tag for certification and load ratingKinking, crushing or other damage that results in detrimentaldistortion of the rope structureBird cagingUnstranding

Unlaying or opening up of a tucked spliceStrand DisplacementCore Protrusion form an opening between strands

Any marked reduction in diameter wither along the entire mainlength or in one section

CorrosionWear or scraping of one-third the original diameter of outsideindividual wires


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Wire Rope Slings


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Wire Rope Slings


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Wire Rope Removal


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Wire Rope Removal

C l l i Sli L d


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Calculating Sling Loads

4 ft

5.656 ft

Load Angle Factor = Sling Leg Length Height from Pick Point

Load x Load Angle Factor Number of Sling Legs = Tension in Each Sling Leg


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10,000 lbs

8 ft

4 ft

10,000 lbs

8 ft8 ft

5 ft

4 ft

6 ft

10,000 lbs

8 ft8 ft

5 ft

4 ft

8 ft

Length/Height = Load Angle FactorL/H = Load Angle Factor

L/H = 8/4 = 2(10,000 x 2)/2

20,000/210,000 lbs Tension

L/H = 8/5 = 1.6(10,000 x 1.6)/216,000/2

8000 lbs Tension

L/H = 8/6 = 1.3(10,000 x 1.3)/2

13,000/26500 lbs Tension

(Load x Load Angle Factor)/Number of Sling Legs = Tension in each Sling Leg

Effect of Sling Angle


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Effect of Sling Angle

11025 11195 1173312731

1439217152

22050

90 80 70 60 50 40 30

Degree of Angle

T e n s

i o n

i n P o u n

d s

As the sling angle decreases towards the horizontalthe stress applied to the sling increases.

“ The minimum angle allowed is 30 ”

Halliburton Best PracticesMinimum Sling Angle


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Man \ Aerial Lift


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Man \ Aerial Lift

Man \ Aerial Lift


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• Requires Orientation Course Including Hands onExercise and Skills Test

• Employee’s are Not to Operate Man \ Aerial Lifts Priorto Qualification and Authorization

Man \ Aerial Lift

Dropped Object Statistics


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• Every 3.6 Dropped Object Incidents = 1 Injury

• Every 26 Dropped Object Incidents = 1 Fatality

Dropped Object Statistics

What is a Crane?


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What is a Crane?

• A crane is a mechanical lifting device equipped with awinch, wire rope and sheaves that can be used both tolift and lower materials \ objects and to move themhorizontally.

• It uses one or more simple machines to create amechanical advantage and thus move loads beyondthe normal capability of a human.

Boom Trucks


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Telescopic Boom Sections

Boom Trucks

Base (Heel) Section

Boom rest

Boom lift Cylinder

OptionalFront

Stabilizer

Outrigger

Winch

Load LineLoad HandlingDevice

Operator

Controls

Various Parts ofthe HydraulicMobile Crane orBoom Truck Crane

Turret

Center ofRotation

Crane Configuration


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Crane ConfigurationBoom Length illustrated

with the green line is

measured from the BoomHinge Pin to the Center of

the Boom Tip Sheave

Boom Angle isrepresented with the

blue lines and is theAngle of the MainBoom as compared toHorizontal

Load Radius shown herewith red lines is theDistance MeasuredHorizontally from theCenter of Rotation to the

Center of Gravity of theLoad

Boom Angle is read

from the Boom AngleIndicator on the side ofthe boom


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Center of Gra it & Center of Balance


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Center of Gravity & Center of Balance

The point on the load where the load is distributed evenly in all directions

The balancing point on an object

Crane Leverage & Tipping Fulcrum


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Crane Leverage & Tipping Fulcrum

Area of Operation


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Area of Operation(360 Degrees Chart)

Lift Planning


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Lift Planning

Questions that must be answered prior tomaking a lift:

What is the surface that the crane will be setup on?

Will you be able to level the crane properly?

Are there environmental concerns effecting this lift?

Lift Planning Continued


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Lift Planning Continued

What is the longest radius that will be reached?

What is the heaviest load that will be lifted?

What is the Crane manufacturer’s rated loadcapacity?

What percent of rated capacity will be utilized?

Will this become a Critical Lift ?

Critical Lift Criteria


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Critical Lift Criteria

Weight of the Load exceeds 80% of the cranescapacityComplexity of the Lift “line of sight issues, multiplecranes, etc.”Consequences of failure “loss of life, monetaryvalue, etc.”

Load Handling Devices


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Load Handling Devices

Load Block or Hook Block Headache Ball,Overhaul Ball orDownhaul Weight

Required Information for Rigging


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Weight

Rated Capacity

Manufacturer

Required Information for RiggingHardware

Rigging Safety Guidelines


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Know the Weight of the LoadKnow the Center of Gravity of the LoadMake Load Attachment Above Center of GravityKnow Rated Capacities of Slings and Rigging Gear Inspect All Rigging Gear Prior to UseProtect Slings from Sharp Edges

Allow for Increased Tension Caused by Sling Angle Attach Tag Line Prior to Lift



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Keep Personnel Clear of Lift AreaLift Load a Few Inches and Re-Check RiggingKnow Limitations of Rigging Gear

Start and Stop SlowlyWatch for Obstructions and Power LinesUse Proper Hand SignalsMaintain Load Control

Do Not Forget the Law of Gravity

Operational Aides


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Operational Aides Anti-Two-Block Load Moment Indicator Boom Angle Indicator

Level Indicator

Anti-Two Block


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Anti-Two-Block Alarm

Sensors

Weight

The Anti-two blockswitch prevents a twoblock condition bylimiting the followingcrane functions:

1. Hoist up

2. Boom extension

3. Boom down“depending on

crane configurationor manufacturerspecifications”

A two block

condition iswhen the loadhandlingdevicecontacts theboom tip.

L d M t I di t


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Load Moment Indicator

Boom Angle Indic tor


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Boom Angle Indicator

Level Indicator


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Level Indicator

Changes in Load Radius


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Increase in Load Radius Decrease in Load Radius

Low side Longer Radius High side Shorter Radius



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Changes in Load Radius(Load Swing)



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Possible Capacity Loss When Out of Level

Boom Length and Radius Degree out of Level

1 2 3

Short Boom, Maximum Radius 10% 20% 30%

Short Boom, Minimum Radius 8% 15% 20%

Long Boom, Maximum Radius 30% 41% 50%

Long Boom, Minimum Radius 5% 10% 15%

Outriggers and Ground Conditions


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Crane was tipped with an Unloaded Boom“notice that outriggers were down, but not extended”



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Outriggers are down but not extended



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Safe Operating Practice


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Safe Operating Practice

Side Loading


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Side Loading


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Hand Signals


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A Stop Signal Shall be Obeyed by the Operator

Regardless of who Gives it.

“Whether Verbal or Hand Signal”

Hand Signals


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Signals Shall be Discernable at ALL Times.

“No Response Shall be Mad Unless Signals” areClearly Understood


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Hand Signals


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Hand Signals


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Environmental Effects


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http://photos.guedalia.com/IMG_6219+BW+Fix.JPG


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Working Near Power Lines


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The preferred condition under which the operation can be performed is if the hazard ofinjury or death due to electrocution has been removed.

The following steps shall be taken to assure de - energization of the power lines:

The power company or owner of the power lines shall de-energize the lines.

The lines shall be visibly grounded to avoid electrical feedback and appropriately

marked at jobsite location.

A qualified representative of the owner of the lines or a designated representativeof the electrical utility shall be on the site to verify that all steps have beencompleted and that the lines are not energized.

Durable signs shall be installed at the operator’s station and on the outside of thecrane warning that electrocution or serious bodily injury may occur unless minimumclearances, as specified in Table 2 are maintained between the crane or the loadbeing handled and energized power lines.

Lighting


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Crane operations should cease in advance of storm nearing the area wherecrane operations are being conducted.

The load should be landed, boom retracted and placed back into the boom rest.

As a best practice you may resume work 30 minutes after the electrical storm has passed.

Wind


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Wind

Wet and Boggy

http://photos.guedalia.com/IMG_6219+BW+Fix.JPG


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Cold Weather


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Crane Operations should be shut-down at - 40°F

Manufacturer


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Crane Inspection Form

http://www.manitowoccranegroup.com/MCG_MC/Home/EN/Brandhome.asphttp://www.manitowoccranegroup.com/MCG_NAT/Home/EN/BrandHome.asphttp://www.manitowoccranegroup.com/MCG_GRO/Home/EN/BrandHome.asphttp://www.terex.com/main.php


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Documents

crane safety and awareness presentation