lifting awareness - arbrit safety

WestLake Property Management - Crane Lifting Operations Awareness Training

February, 2007 11.5 Training Pack 26 Feb 07

ARBRIT SAFETY TRAINING AND CONSULTANCYDUBAI - +971-4-331-3815, +971-54-5844386 - [email protected] DHABI - [email protected]

Lifting Awareness

2

Training Agenda

• Objectives

• Crane Hazards

• Crane Basics

• Crane Safety

• WL PM Lifting Procedure

• WLPM Permit Process

Training Agenda

3

Objectives

• Review hazards associated with cranes

• Review crane and rigging basics for common types of industrial and construction cranes

• Review crane safety prevention

• Explain WLPM Lifting Procedure Requirements

• Ensure that supervisors, riggers, and crane operators understand and apply crane safety principles and WLPM Permit procedures

Objective

4

Crane Hazards

• Over 250,000 cranes in operation − 125,000 in construction − 80,000 general and maritime

• 80 fatalities per year

• One death per thousand crane operators in their working lifetime (45 years)

• Risk to citizens and other workers

Crane Hazards

5

Crane Hazards

• Major causes of crane accidents − Contact with energized power lines − “Under hook lifting device” − Overturned cranes − Dropped loads − Boom collapse − Crushing by the counter weight − Improper outrigger use − Falls − Rigging failure

Crane Hazards

6

Crane Incidents

• Operator error (33%)

• Support Failure (31%)

• Failure to Use Outriggers (22%)

• Machinery and Structural Failure (11%)

• High Winds (2%)

Crane Incidents

7

Controlling Crane Hazards

• Operator Requirements − Knowledge (Training) − Skills (Demonstration)

• Inspection − Frequent

− Daily, monthly − Hooks, rope, crane operation

− Periodic − At least annually − Complete inspection - wear, damage, deterioration, operation − Slings

• Testing • Records

Controlling Crane Hazards

8

Crane Types

• "Industrial cranes“ − Overhead − Gantry − Jib

• "Construction cranes“ − Mobile − Tower − Derricks

Crane Types

9

Industrial Cranes

• Overhead Cranes − Common in industrial facilities − Supported by overhead rails − Components − Bridge − Trolley − Hoist

− Often pendant or remote operated − Easy to use, little training required, no stability problems

Industrial Types

10

Industrial Cranes

• Gantry cranes − Similar to overhead cranes, but

supported by a mobile frame which travels on the ground

Small (1000 – 10,000 pound capacity) gantry crane

Large (600 ton capacity) gantry crane

Industrial Cranes

11

Industrial Cranes

• Jib cranes − Pivot mounted boom with

trolley and hoist

Wall-mounted jib crane

Floor-mounted jib crane

Industrial Cranes

12

Construction Cranes

• Mobile cranes − Crawler cranes − Truck cranes − Hydraulic cranes Boom telescopes May have jib

− Equipped with outriggers for stability

Construction Cranes

13

Construction Cranes

• Tower cranes − Variable height

“climbing cranes”

− Used for building construction

Construction Cranes

14

Construction Cranes

• Derricks − Boom angle changes to adjust

horizontal distance − Often used in shipyards, building

construction, etc. − Gin pole − Chicago boom − Stiff-leg − Etc.

Stiff-leg construction derrick

Construction Cranes

15

Rigging Basics

Wire rope • Usually a "core" member to increase

flexibility − Fiber Core (FC) − Wire Strand Core (WSC) − Independent Wire-rope Core (IWRC)

• Classified by strand and wire count

− 6 x 31 IWRC is common rope for overhead cranes, with 6 strands of 31 wires each and a core

Rigging Basics

16

Rigging Basics

• Fittings, sheaves − Shackles − Blocks − Sockets − Hooks

− May have safety latch − Eyes − Turnbuckles

Rigging Basics

17

Rigging Basics

• Always use rigging to connect the load to the hook • Materials

− Wire rope − Fabric − Chain

• Slings − Straight (regular) − Choker − Basket − Double, triple, etc.

Rigging Basics

18

Why Crane Safety? Crane Safety

19

Preventing Crane Accidents

• Contact with energized power lines (45% of accidents) − De-energize lines − Maintain minimum distance

− 10 feet distance for 50 kv − Over 50 kv, add 4 inches per 10 kv

− Use proximity alarms − Warn when energized line is near − “No fatalities” in 25 years, according to mfg.

− Warning signs

Why Crane Safety

20


• Dropped loads − Operating anti-two block device (upper limit switch) − Proper rigging − Inspection

• Boom collapse − Inspection − Stable base − No overloading − No horizontal loading

• Crushing by the counter weight − Stay away from the rear of the crane


21


• Rigging failure − Inspection − Proper use

− temperature, angles, etc. • Falls

− Fall protection for workers suspended by crane "man basket" or "suspended work platform“

− Secure fall protection “above the hook”

Why Crane Safety


22


• Under hook lifting device problems − Inspect, proper use, etc.

• Overturned cranes − Assure a level and stable base for the crane − Comply with load charts Weight Boom angle and extension Only vertical loads

− Wind can cause a significant side load


23

WL PM Lifting Procedure

• Permit • Task Safety Analysis / Risk Assessment • Pre-Job Planning Meeting • General Requirements • Equipment Requirements • General Safety Rules • Lifts / Critical Lifts • Competency • Cancellation of Permit • Completion of Permits • Training

Lifting Procedure

24

Permit

− Must obtain a Lifting Permit prior to doing any lifting work

− Permit Form required

− All workers must sign the permit form

− Permit must be posted at job site

− Permit is valid for one shift or 12 hours

− Permit cancelled if emergency alarm, fire alarm, or facility emergency occurs

Other permits may be required (e.g., Hot Work)

Permit Permit

25

Task Safety Analysis / Risk Assessment Task Safety Analysis

A TSA is required Must be completed by all Lifting work team members Review Work, # of workers, tools/equipment, PPE Method of lift Competent people assigned to lift Equipment inspections Applicable procedures / cautions based in specific lift

equipment Emergency plan

Risk Assessment Level 2 Risk Assessment required for Critical Lifts Must be discussed in daily planning meetings

Task Safety Analysis

26

Pre-Job Planning Meeting

• Held prior to any Lifting Operations activity to discuss the Task Safety Analysis (TSA), Level 2 risk assessments, Lifting Plan, Lifting permit, checklists, Emergency Response Plan and SIMOPS.

• Meeting minutes and signed attendance list shall be documented.

• Minimum requirements for discussion: − Review hazards, safe work procedures, permitting requirements,

etc., − Competent Person (CP) present at job site, − “Stop the Job” responsibilities to address potential unsafe

conditions, − Use of Personal Protective Equipment (PPE), − WLPM notification requirements for all accidents, injuries, first aids

and near miss incidents.

Pre Job Analysis Meeting

27

General Requirements

• Every lift requires a lift plan − Lift plans shall be documented

− Use calculation sheet

− Critical lift assessment must be performed before every lift

• Critical Lifts (80% crane capacity) require additional steps − See WLPM Lifting Operations Procedure for additional criteria to

define a Critical Lift


28


An anti-two blocking device is equipment, which prevents the load blocks from coming into physical contact with the head, or crown, blocks, which can result in damage to the lifting equipment and a dropped load. Anti-two block devices must be installed on all cranes and hoists and must be kept operational. Bypassing this device for any reason is prohibited.

All cranes, chain hoists, and lifting equipment shall be tested, inspected and maintained in accordance with the applicable safety and health regulations and this program.

Only competent operators, lift leaders and riggers shall perform lifting operations.

Backhoes, track hoes, front-end loaders and similar earth moving equipment may be used only for minor incidental lifting. Such use of this equipment shall comply with the equipment manufacturer’s requirements, specifications and designs for lifting use.

The command STOP may be given by anyone and must be obeyed by everyone including the crane or hoist operator.


29

Lifting will not commence unless an assessment of the lift has been completed and a competent person has determined the lift method and equipment.

Lifting will not commence unless the load does not exceed the

dynamic and/or static capacities of the lifting equipment. Lifting will not commence unless safety devices installed on

lifting equipment are operational. Lifting will not commence unless a competent person has

visually examined all lifting devices and equipment before each lift.

General Requirements General Requirements

30

Equipment Requirements

WL PM Lifting Procedure has requirements for the following equipment: − Overhead Cranes and Hoists − Mobile Cranes − Tower Cranes − Wire Ropes, Chains, and Slings

Require preventative maintenance program based on manufacturer’s recommendations

Requires inspection and equipment condition based on manufacturer’s recommendations

Equipment Requirements

Lifting Procedure

31

Crane Inspection

• Annual Inspection is done by a third party certified competent person and any time a crane is assembled prior to being put into service

• Monthly Inspections are done prior to use and each month thereafter by a competent person

• Daily Inspections are done prior to each shift by a competent crane operator

• Any defective equipment will be repaired before use

Crane Inspection

32

General Safety Rules

Standard Hand Signals shall be in accordance to OSHA regulations

Signal Person Qualifications − Prior to signaling crane operations, all signal persons shall be

tested and demonstrate their qualifications in the following areas: Basic understanding of crane operation and limitations,

Standard hand signals described in WLPM Lifting Operations Procedure, Attachment # 1, “Standard Hand Signals for Crane Operators”, whenever hand signals are used,

Standard voice signals are defined and used, whenever voice signals are used.


33


• Signal Person Qualifications − Know the crane limits − Keep persons outside the crane’s operating area − Have an unobstructed view of the load and crane or use a

second signal person − Never direct a load over a person − Keep load clear of obstructions − Never let the boom contact the load or another object − Anyone can give an emergency stop signal


34


Moving and Lifting the load − Each lift shall have a TSA completed prior to the lift.

− Each lift involving two or more persons shall have a signal person.

− Hoisting and rigging operations for all lifts require a designated lift

leader, who shall be present at the lift site during the entire lifting operation. The designated lift leader shall make certain the load is correctly rigged. It is recommended that Lift Leader not be the same person as the crane operator.

− All personnel in the vicinity of the crane operations who are not directly involved with the lift shall stay out of the area of maximum boom radius. If necessary, the area shall be barricaded to keep personnel out.

− Loads shall not be carried over people. Personnel shall not pass under suspended loads or the loaded crane boom. Never allow anyone to get close or under the load.


35

General Safety Rules Moving and Lifting the load − Work on suspended loads is prohibited. Suspended loads include

the lifting hook, rigging, spreader bars and any other attachments below the lifting hook.

− No one shall be on the load, hook or rigging during hoisting, lowering or swinging of the load, or traveling of the lifting equipment except as noted in the Critical Lifts section this procedure.

− If the load must remain suspended for any considerable length of time, the load shall be physically immobilized with a positive acting mechanical

− Tag lines shall be used to control the load. Tags lines will minimize the danger of grabbing or touching the load. Usually at least two tag lines are needed.

− The load shall be secured and balanced in the sling or lifting device before it is lifted more than a few inches.


36

Lifts

Lift leader shall be present at the site during lift operations.

A Task Safety Analysis and Level 2 Risk Assessment shall be completed when the velocity of wind exceeds 20 mph, or lower if so indicated by the manufacturer. Do not lift loads when winds create an unsafe or hazardous condition, regardless of wind speed. Lifting operations shall be suspended when wind speeds reach 30 miles per hour.

If the visibility of the riggers, hoist crew or load is impaired by weather conditions such as dust, snow, rain, fog or darkness, lifting operations must be suspended.

All employees shall be kept clear of loads about to be lifted and of suspended loads. It is recognized that operators on WLPM construction projects may work in direct proximity to suspended loads and may have portions of their bodies under the load.

All personnel shall keep hands out of pinch points while slack is removed from slings and load lines.

Lift

37

Lifts

The gross load should not exceed the dynamic or static capabilities of the lifting equipment. An evaluation of crane capacity shall be completed for each lift and kept for the duration of the job. Any load exceeding 80% of the rated crane capability, at the boom angle that is required to complete the lift should be considered a Critical Lift.

Power lines are a high potential hazard during any lifting operation. Power lines within twice the maximum swing radius of the crane, plus the required clearance, constitutes a Critical Lift.

The minimum clearance between the maximum boom extension, load or load line and a power line is ten (10) feet for all voltages up to 50 kilovolts (kV). Higher voltage lines required greater clearances as indicated below.

Normal Voltage (phase to phase) Minimum required clearance

To 50 kV 10 ft. Over 50 to 200 kV 15 ft. Over 200 to 350 kV 20 ft. Over 350 to 500 kV 25 ft. Over 500 to 750 kV 35 ft. Over 750 to 1000 kV 45 ft.

Lift

38

Critical Lifts

Additional precautions shall be taken for operations determined to be Critical Lifts. A critical lift is one in which the dropping, upset, or collision of parts, components, or assemblies, could present a potentially unacceptable risk of personnel injury or property damage. Or it is a lifting designated as a critical lift by the project because of special circumstances or hazards.

The designated lift leader in charge of each critical lift shall prepare a Task Safety Analysis (TSA), Level 2 Risk Assessment (RA), lifting permit and a critical lift plan for safe performance of the lift. The critical lift plan, TSA and RA must be communicated to, discussed with, and approved by all personnel involved in the critical lift.

During Critical Lifts a diagram of the lift and rigging must be prepared.

Critical Lifts

39

Critical Lifts

Examples of critical lifts include, but are not limited to: – Lifts exceeding 80% of the crane capacity.

– Lifting of personnel. All Lifts of personnel utilizing man baskets

must conform to 29 CFR 1926.550 (g); to include a test lift prior to personnel being lifted.

– Lifting where electric power lines are within twice the maximum swing radius of the crane, plus the required clearance.

– Lifting where the crane operator cannot see the load.

– Lifting directly over energized or pressurized equipment.

– The use of two or more cranes to simultaneously lift one load.

Critical Lifts

40

Critical Lifts

Examples of critical lifts include, but are not limited to: − Lifts to be made over normally occupied facilities

− When ever the value of the replacement of the item being

lifted is excessive.

− When ever the replacement time for the item lifted exceeds two months.

Critical Lifts

41

Developing a Critical Lift Plan

The written Critical Lift Plan shall include: Determine maximum radius/boom length

Determine type/capacity/size of crane

Determine rigging equipment needs

Complete lifting diagrams, critical lift permit

Make the required schematics to determine the necessary configuration of crane, head room and reach

Check capacities vs. total loads lifted including appropriate deductions

Determine rigging equipment needs Determine any secondary notifications that need to be made

Developing a Critical Lift

42

Critical Lift Precautions

• Pre-lift Checklist • Power line protection measures • Safe rigging practices employed • Lifts in tight quarters, over process/normally occupied facilities

minimized • Ground stability for the crane adequate • Tag line(s) in use; if appropriate • Orientation of load • Methods to connect and disconnect load • Weather conditions

Critical Lifts Precautions

43

Lifting Permit

The Lifting Permit must be completed prior to operations using a mobile and tower crane, or any lift determined to be a Critical Lift.

The following guidance is provided for completing the Lifting Permit.

− All permit line items shall be completed. Signatures are required on the permit.

− The load weight should include the weight of the load, block, ball, lattice extension, jib, hoist rope, rigging and any other weight that would affect the gross load.

− The crane / hoist must be inspected as required by the applicable Standard.

− A Critical Lift Assessment must be performed before every lift. A “YES” response to any of the critical lift criteria listed above requires the lift leader to perform a Critical Lift Plan.

Lifting Permits

44

Lifting Permit

– Procedures that call for the lifting of personnel by a crane or derrick are prohibited, unless it can be demonstrated that no other means are available or that all other options are more hazardous. If personnel need to be lifted by means of a crane it is a Critical Lift. The mandatory requirements for lifting personnel can be found in the OSHA regulations 29CFR1926.550(g).

– When eye bolts or other lifting attachments are used they must be verified to be of sufficient strength and used in accordance with the manufacturer’s requirements. The name of the individual that has verified the mode of attachment must be entered in the permit.

– During the planning of the lift, if clearances from structures are a concern, an individual must be stationed so they can observe the clearance and warn of any impeding danger.

– If the potential exists for people to move into the area of the lift, a person shall be assigned to control access to the area.

Lifting Permits

45

Lifting Permit

– During Critical Lifts a diagram of the lift and rigging must be

prepared.

– Any exception to the critical lifting procedure must be approved through the MOC process.

– Expired Lifting Permits shall be kept on file at the Westlake Property Management office for one year beyond their expiration date.

Lifting Permits

46

Competency

Competency of lifting personnel must be provided with Lifting Plan – Lift Leader – Crane and Hoist Operator – Rigger – Signaler

● Meet requirements outlined in procedure

CompetencyCompetency

47

WL PM Lifting Procedure

Cancellation of Permits – Any alarm affecting the area of permit (evacuation, fire, etc.) shall

immediately void permit – Workers shall immediately follow required procedures – New permit required upon return

Completion of Permit

– When work complete, the Lifting Supervisor (Performing Authority) shall complete permit and return to Issuing Authority

– Permits kept on file

Training – Company shall provide training programs for their personnel involved

in lifting to meet safety and health regulations. Requirements are described in procedure.

– Personnel to attend WL PM Awareness and Permit training

Lifting Procedure

48

Emergency Response Plan

General Requirements: • Site Specific ERP required.

• Must be documented and reviewed at the pre-job planning meeting.

• Must be available at the work site at all times when work is being performed.

• Personnel must be trained to use and carry out the plan before work begins.

• Emergency Response Plan must include: − Facility contact names and phone numbers, − Energy System Isolation procedures that address accidental contact of

any overhead utilities that have not been de-energized, − Muster area, − Phone numbers for emergency services and directions to work site.

Emergency Response PlanEmergency Response Plan

49

Hard hats and safety glasses must be worn

Steel Toe Shoes/Boots are required on all construction sites

Warning vests must be worn when exposed to traffic

Emergency Rescue Equipment such as Safety Harness, Lifelines and other rescue equipment must be available when hazardous conditions exist or may develop.

Personal Protective Equipment Personal Protective Equipment

50

High Visibility Clothing

WL PM requirement for outdoor

construction sites,

especially around Heavy

Equipment

High Visibility Clothing

lifting awareness - arbrit safety

Documents