Scotford Safe Work Practice

Scotford

Safe Work Practice

Department:

ALL DEPARTMENTS

Document Number:

SCT-HSSE-SWP-4412

Subject:

LIFTING AND HOISTING

Owner:

HSSE MANAGER

(Note: Current versions of approved documents are maintained electronically. Printed copies are uncontrolled)

Uncontrolled document was printed on: 2020-02-29

Effective Date: 2018-11-26 Rev. 3 Page 1 of 28

TABLE OF CONTENTS

Purpose ................................................................................................................... 2

Precautions ............................................................................................................. 2

Training Requirements ............................................................................................ 3

Responsibilities ....................................................................................................... 4

4.1 Crane Operator Supervision .......................................................................... 4 4.2 Lift Supervision - Shell Supervisor/ Contractor Supervisor ............................ 4 4.3 Crane Operator .............................................................................................. 5 4.4 Rigger ............................................................................................................ 6

4.5 Signal Person ................................................................................................ 6

Key Points ............................................................................................................... 7

5.1 Crane Operation ............................................................................................ 7 5.2 Crane Inspection and Maintenance ............................................................... 8

5.3 Lifting/Hoisting ............................................................................................... 9 5.4 Rigging ......................................................................................................... 10 5.5 Inspection, Testing and Certification of Rigging ......................................... 133

5.6 Lift Categories .............................................................................................. 15 5.7 Working in Close Proximity to Suspended Loads ........................................ 17

5.8 Crane Suspended Personnel Baskets ......................................................... 17 5.9 Tag and Hoisting Lines ................................................................................ 22

References ............................................................................................................ 22

Implementation ...................................................................................................... 22

Interpretation and Updating ................................................................................. 222

9.0 Appendices ……………………………………………………………………………....23

Glossary of Terms……………………………………………………...23

Lift Review Flowchart………………………………………………….244

Interpretation and Clarification of LSR # 7…………………………25

Non-Routine Simple (Critical) Lift Planning and Authorization…..27

Non-Routine Complex Lift (Engineered) Checklist ........................ 27

Crane-Suspended Personnel Basket Authorization ..................... 27

Lift Categorization Example......................................................... 28

10 Questions for Safe Lifting and Hoisting ................................. 28

Lift Planning Template .................................................................. 28

Subject:

Lifting and Hoisting

Document Number:

SCT-HSSE-SWP-4412



Purpose

This safe work practice (SWP) establishes standards of practice for operation and maintenance of cranes and hoists at Shell Scotford (SCT) site. Cranes and hoists include mobile cranes of all types, bridge cranes, tower cranes, monorails, jib cranes, vessel davits, chain falls, come-alongs, and Tirfor winches, or similar. It does not include fork lifts, elevators or Gin wheels (scaffolded lifting pulley systems). All employees and contractors must comply with the requirements described in this SWP. All cranes and rigging shall be operated and used in accordance with this SWP. A Glossary of Terms is presented in Appendix I.

Precautions

2.1 Cranes, hoists and rigging shall be designed, manufactured, installed,

operated, tested, maintained and repaired to meet the standards set by

Canadian Standards Association (CSA) Standards, Occupational Health

and Safety (OH&S) Code and the manufacturer’s specifications.

2.2 Any container, including tool bags, used for lifting must be designed for that

purpose and be labelled with its maximum load rating. Containers must be

inspected for damage by a competent worker prior to use.

2.3 All lifts at SCT must have an initial review according to the Lift Review

Flowchart, Appendix II.

2.4 Hoisting will be suspended when an electrical storm is imminent, unless the

hoisting is performed indoors or under a permanent roof.

2.5 Hoisting operations performed during hours of darkness or limited visibility

shall have lighting and signalling arrangements that are adequate for the

crane operator.

2.6 Operators of powered mobile equipment shall maintain the operator cab’s

floor free of materials, tools or debris that may interfere with safe operation

or create a tripping hazard.

2.7 No person shall walk or work under a suspended load (Life-Saving Rule

#7). If access under the load is required, secure the load by setting it on

cribbage or blocking. Refer to Appendix III for details.

2.8 Any portable building/trailer, including blast-resistant modules (BRMs),

within the red flagged-off area for a lift must be empty of all personnel and

taped off with “Danger Do Not Enter” tape for the duration of the lift. Refer to

Appendix III for details.

2.9 Concrete bridges and culverts throughout SCT site have restricted vehicle

weight loading.

Subject:


Document Number:

SCT-HSSE-SWP-4412



• Signs indicating allowable vehicle loads shall be posted at all bridge, culvert, and buried pipeline road crossing locations.

• Cranes weighing more than the posted allowable weights, or with a missing sign, will require written approval from Shell’s Engineering Department.

• Crane operators shall verify that all culvert crossings are acceptable for travel.

• If in doubt about the acceptability of a bridge or culvert crossing, consult Shell’s Engineering Department for approval.

2.10 The following actions are prohibited on SCT site:

• Exerting any horizontal pull at an angle to the crane that will affect the crane's capacity in any manner.

• Attempting any lift where wind speed, including wind gusts, exceeds manufacturer’s recommendations at the individual crane location.

• Travelling on any road with the jib extended, without the help of a spotter (boom walker).

• Lifting and hoisting loads over areas where people are present. Refer to Appendix III for details.

• Casting a load in an attempt to set it down at a point beyond the crane’s normal reach.

• Exerting a vertical pull on any restrained object. Loads shall be released /unrestrained by other mechanical means prior to lifting, even if the crane is equipped with a load indicator.

Training Requirements

3.1 Workers involved in lifting and hoisting work on SCT site must be familiar

with the requirements of this SWP.

3.2 For mobile cranes 15 tons or greater, Operators shall hold a valid

qualification certificate provided by Alberta Manpower Development Act for

heavy equipment operators (Crane and Hoist Equipment), Red Seal

qualification, or a valid Journeyman’s ticket from the Operator’s country of

origin and shall be tested for competency by their supervision.

3.3 For mobile cranes less than 15 tons, Operators shall be trained by a Shell

approved training program and tested for competency at site. They must

also possess a valid journeyman’s ticket that includes rigger training or an

equivalent certification from a Shell approved training program.

3.4 Operators of fixed cranes shall be trained and qualified in hoisting and

rigging for the cranes that they operate.

3.5 Crane operator apprentices shall be under the supervision of a journeyman

operator at all times until deemed capable of operating a crane without

constant supervision by their site supervision.

3.6 Crane operators must be able to conduct equipment maintenance checks to

ensure the equipment can safely handle all loads within the scope of work.

Subject:


Document Number:

SCT-HSSE-SWP-4412



3.7 Crane operators must be familiar with the hoisting equipment to be operated

and shall be given sufficient time to adequately check out and test the

equipment.

3.8 Boom Truck Operators require a Boom Truck Operators Certificate from the

Alberta Government, or a valid hoisting ticket.

3.9 All riggers must possess a valid trade ticket that includes rigger training or

an equivalent certification from an accredited training program. Site

supervision shall confirm that all riggers are competent prior to conducting

any rigging activities.

Responsibilities

4.1 Crane Operator Supervision

Ensure the crane operator is trained, experienced and competent to operate a crane.

Ensure the crane operator fully understands the load chart and can determine the crane’s net capacity for all operating conditions.

Provide ongoing training for all crane operators to ensure a consistent high level of competence.

Ensure site supervision is aware of their responsibilities and what work must be done to prepare the site for a lift.

Ensure the crane and associated equipment is operated and maintained in accordance with the manufacturer's requirements and all inspection and maintenance records are retained and available on request.

Ensure the crane has a valid annual inspection certificate.

4.2 Lift Supervision - Shell Supervisor/ Contractor Supervisor

Person In Charge (PIC) Provide a well-prepared working area per DEP 60.00.10.13, Mobile

Crane Foundation Assessment for the mobile crane before it arrives on site, that includes ensuring the following:

• access roads are prepared

• operating locations are graded, levelled, checked for voids and compacted, if applicable

• sufficient space is available to erect/extend the boom

• blocking is used to support the boom during assembly or disassembly

• blocking/matting is used under outriggers

• operating locations are sufficiently far away from power lines, excavations or buried utilities

• flagging or barricades are positioned to prevent access to operating area especially behind the crane

Determine the correct load weight and radius and inform the crane operator.

Supervise the rigging crew.

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Document Number:

SCT-HSSE-SWP-4412



Ensure the signal person and rigger are competent and the signal person is knowledgeable of the international hand signals in the industry and at SCT.

Designate certified riggers and signal person to the crane operator (in many cases, the rigger and signal person are the same person).

Ensure all involved personnel in the operation understand their jobs and responsibilities.

4.3 Crane Operator

Ensure safety of the crane operation.

• If there is a concern that the lift might be dangerous or unsafe, work must stop until the hazard is addressed and conditions for a safe lift are assured.

Be familiar with and follow the crane's operating manual and load

chart.

• Must understand the correct meaning of all notes and is capable of calculating the crane's net capacity under all possible conditions.

Ensure the crane is inspected and maintained as prescribed by the owner and the manufacturer.

Inform the crane owner of any maintenance required by the crane by writing in a logbook, an inspection report, or work request.

Confirm that the site is adequately prepared for the crane. Review the planned lift with site supervision and the crew. Perform final checks before making the lift. Know the weight of the load and rigging.

• The crane operator is not responsible for determining these weights but must know them.

Assemble, set up and rig the crane properly. Maintain communication with the signal person. Stop the lift in case of inadequate communication or loss of

communication. Determine the location of load placement. Remain in the crane, seated properly and attentive, at all times when

the load is off the ground. Move the crane, as required. Be aware of boom deflection during heavier lifts. Remove the anti-two-block when the associated line is not installed. Shut down and secure the crane when it is not operating. Complete the Non-Routine Simple (Critical) Lift Planning and

Authorization (Appendix IV) if the load exceeds 75% of the crane’s

capacity. Review the lift hazard assessment with the crew working with the

load. If operating a mobile crane, determine when to lift if wind becomes

a concern. Notify the Production Team Member if a portable building/trailer is

observed within the red flagged-off area for a lift.

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Document Number:

SCT-HSSE-SWP-4412



4.4 Rigger

Discuss lift requirements with the crane operator and designated signal person, and sign onto each other’s Job Hazard Assessment/Field Level Risk Assessment (JHA/FLRA).

Assist in setting up the crane. Ensure proper sizes and types of rigging are used to lift the load. Attach rigging securely to the load. Apply softeners over any sharp edges that may cut the lifting sling.

Good trade practice shall be used to select the type and material of the softener. If in doubt about application of a softener in a particular or special situation, consult Shell’s Engineering Department for approval.

Visually check rigging for wear and replace, if required. Use tag lines on loads. Relay signals to the designated signal person, when required. Ensure adequate blocking is ready to set loads on.

Ensure the load is free from all obstructions before attempting the lift. Check the position of rigging for binding when the load is being

moved. If final alignment cannot be done freely, align by mechanical means

such as wedges, drift pins, jacks, come-alongs or chain falls. Ensure proper tools and equipment is available to secure the load

when set into position.

4.5 Signal Person

Supervision shall confirm that Signal Persons are competent with hand and radio signalling.

Discuss lift requirements with the crane operator and the rigger, and sign onto each other’s JHA/FLRA.

Guide and direct the mobile crane in and out of congested areas. Flag off the load path with RED “Danger Do Not Enter” flagging prior

to lifting. As part of this activity, the signal person shall walk down the entire lift area, including at other elevations to ensure flagging is three dimensional. Refer to Appendix III for additional information.

Ensure the crane boom does not strike any equipment or power lines. Ensure the crane can move without making contact with any

obstructions. Ensure the crane operator and rigger understand the signalling

method to be used. Obtain lifting radios and establish the signalling method with the

crane operator when visibility will be obstructed. Monitor the load hook(s) to prevent them from two blocking.

Notify the crane operator of any unusual or unexpected boom deflection or load movement on any lift.

Wear an armband to identify as the signal person.

Subject:


Document Number:

SCT-HSSE-SWP-4412



Flag off any portable building/trailer that is within the red flagged-off area for a lift with RED “Danger Do Not Enter” flagging. Ensure all the buildings are empty prior to flagging.

Remove the flagging when the lift is complete.

Key Points

5.1 Crane Operation

When two or more cranes are working in close proximity, make provisions to prevent contact between cranes, adjacent equipment or structures.

• There must be suitable communication between crane operators and a signal person to coordinate crane movements.

• If two cranes are working on the same lift, more than one signal person may be required depending on the nature of the lift.

Every crane must have a load chart that can be accessed by the operator.

• For mobile cranes, load charts shall be accessible in the cab.

• For fixed permanent cranes, design documents will be available in the reference library and the crane shall be marked with the allowable load permitted throughout the working range of the crane.

• Hoisting equipment with dual controls must have load charts at each set of controls.

Crane operators must not rely on "feel" to determine when the crane capacity is reached.

• The operator must know the total weight of the load being lifted as well as the radius for mobile cranes.

Load weights must be determined by one of the following methods:

• Certified scale weight, if available

• Load indicators

• Calculated weight completed by a qualified individual

• Weight tables

• Weight from original vendor drawings with allowances for scale, sludge, and internal components

• If in doubt about the weight, a calibrated load cell shall be used to determine the exact weight

Load indicators shall be calibrated and certified as per manufacturer’s instructions at specified intervals.

All loads must be free and clear to lift, avoiding any possibility of

shock or impact loading of the hoisting equipment. During normal operation, the crane operator must remain in control

of any suspended load. When left unattended mobile cranes shall be secured with brakes

and mechanical locks (dogs) per manufacturer’s instructions.

• If this is not practical, the boom shall be lowered to 70* or lower from the horizontal and positioned with winds coming from the rear of the crane.

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Document Number:

SCT-HSSE-SWP-4412



Fixed permanent cranes shall be stored in a location that does not interfere with normal activities.

Work shall not be done within 7 metres of an energized overhead power line, pole or associated guy wire. For Approach Distances of less than 7 metres an Overhead Power Line Encroachment Authorization is required. Refer to SWP SCT-HSSE-SWP-4416 for details.

5.2 Crane Inspection and Maintenance

The owner or supplier of a mobile crane shall arrange for competent personnel to conduct daily, weekly or other inspections as recommended by the manufacturer's specifications and the OH&S Code.

Fixed permanent cranes and hoists shall be inspected and maintained in accordance with the manufacturer’s instructions or instructions as certified by a professional engineer, who is experienced and competent to perform these inspections.

Mobile crane operators shall ensure a current crane logbook is maintained and kept in the crane cab at all times. It should include records of the following:

• inspections

• repairs

• tests of safety devices, where applicable

• rigging information

• hours of service

• any other operational record recommended by the manufacturer

• daily preventive maintenance checks

• load cell calibration (every 6 months) on conventional friction cranes or where not an intrinsic part of the load management system

Records for fixed cranes and hoisting equipment not specific to mobile cranes shall be kept in a central location on SCT site.

• Records as specified by the manufacturer for each hoisting and rigging equipment shall be maintained until that equipment is disposed of.

• Rigging and hoisting components supplied by contractors shall have equipment records and equipment inspections maintained by the contractor in accordance with the manufacturer’s instructions.

For mobile cranes, a structural worthiness certificate approved by a professional engineer shall be kept on file for each crane and upon

request shall be accessible to audit on site.

• The certificate shall verify that the structural integrity of all load-related components have been tested and witnessed and required repairs have been made.

• Examinations shall be done every 12 months or 2,000 hours of crane operation, and shall include the following:

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Document Number:

SCT-HSSE-SWP-4412



• Non-destructive test of the crane boom, mast, counterweight attachment, jib and outriggers

• Load lines, pendants, slings and cables shall be visually inspected for wear prior to each use

• Non-destructive test for all load carrying equipment such as sheaves, blocks, shackles, hooks, and cables clips

• Attachment of crane to carrier at point of rotation

• Winch brakes

• Boom stops

5.3 Lifting/Hoisting

Note: Sections 5.3.2 to 5.3.7 do not apply to fixed cranes. All lifts require pre-lift communication with all involved parties to

discuss the lift.

• Designate the signal person, rigger and tag line holder.

• Discuss the lifting procedure, wind, weather constraints and adjacent hazards.

• Assign a member of the lift team to the task of keeping non-involved personnel clear of the area by red flagging off the load path.

For lifts performed using the "Outriggers" section of the capacity chart, the following criteria shall apply:

• All outriggers must be fully extended

• Crane wheels must be clearly 2 to 3 inches off the ground

• The crane must be level to within 1 degree Any derating of crane capacity or rigging shall be in writing and shall

only be performed by the equipment manufacturer or a professional engineer.

• A crane must be derated as follows:

• If the outriggers cannot be fully extended for any reason, derate the crane to “on rubber” capacity chart or the partially extended outrigger chart, if available.

• If the manufacturer or a professional engineer recommends derating should be applied (i.e., cold weather, etc.).

In the absence of manufacturer’s recommendations or documentation with respect to minimum design temperatures for a crane or rigging equipment, -25°C shall be used as the point where derating shall be considered.

All radius checks must be confirmed by the crane operator with a measuring tape or other suitable measuring device.

The ground under the crane must be compacted or proven stable to both the crane operator and Shell Job Owner’s satisfaction per DEP 60.00.10.13, Mobile Crane Foundation Assessment.

• A crane on outriggers must use pads or blocking underneath to spread the bearing loads.

• This also includes outriggers placed over sewer lines or other underground voids.

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Document Number:

SCT-HSSE-SWP-4412



• For Non-Routine Complex (Engineered) lifts, ground stability must be verified.

The full swing radius of a crane’s counterweight shall be red flagged off for the duration a crane is sited in a particular location, unless it is stowed and parked in its designated storage location.

Tag lines shall be used at all times when practical where a danger is created by the movement of the load being hoisted.

• If use of tag lines is not practical, a short line (8 to 10 feet in length) shall be attached to the load to allow the worker to catch the load.

The following information must be known for all lifts:

• Total load weight below the hook

• Effective weight of jib and ball, where applicable

• Weight of rigging, load block and hoist line

• Percent capacity of allowable load calculated, verified by a load cell

• Wind velocity, at the specific crane location

• Operator visibility In addition to the requirements in Section 5.3.9, the following must

be known for lifts by mobile cranes

• Boom length

• Maximum radius

• Soil conditions, including underground piping/sewers load limits

• Impending weather

• Proximity to other structures (minimum 2 feet clearance for all components, the boom, and the counterweight is required). If the minimum clearance is not possible, the pre-job checklist must address the equipment contact and personnel pinch point issues.

5.4 Rigging

General Requirements

• Rigging includes, but is not limited to, wire rope, polyester, Kevlar®, and nylon slings, as well as come-alongs, chain falls, shackles, hooks, spreader bars and other load bearing hoisting attachments.

• The safe working loads (SWLs) of each rigging component shall be based on a minimum 5 to 1 safety factor.

• All rigging components used for hoisting personnel shall be based on a minimum 10 to 1 safety factor.

• Working loads on rigging shall not exceed the SWL limits established by the manufacturer, or in their absence limits established by a professional engineer.

• No hoisting or rigging equipment shall be marked for identification using methods that may adversely affect the capacity of that equipment.

• No rigging shall be used unless it has been inspected and identified within the past 12 months.

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Document Number:

SCT-HSSE-SWP-4412



• Contractors who bring any rigging to SCT site must prove that it has been inspected in the past 12 months.

• A Shell contact person shall verify that the inspection is current.

Slings

• When slings are applied to sharp edge loads, the sharp edges must be protected with softeners to prevent damage to the slings.

• Synthetic slings should be double wrapped when used in choke application, when there is a risk of slippage.

• The SWL of wire slings, when bent around pins or over hooks, shall be reduced according to manufacturer’s specifications.

• Slings shall only be used with the correct size shackle to prevent bunching-up of the sling. Derating of slings due to bunching is not permitted.

• Chain slings shall not be used for rigging on SCT site, except for permanently installed chains on submersible pumps located in below grade sumps, or manufacturer provided chain slings required for mobilization and demobilization on larger cranes.

• When removing these sump pumps the area must be barricaded such that no person would ever be under the load being lifted.

Shackles

• Shackles shall be used with the pin to the eye of the sling or lifting lug.

• Pins shall not be in contact with the running part of any sling.

• The shackle pin must be straight and of the correct diameter. The shackle pin threads must be fully engaged.

• Bolts shall not be used as substitutes for shackle pins.

• Shackles shall have the pins secured if shackles are used as a component for hoisting personnel.

Hooks

• All hooks shall have functional safety latches.

• Hooks and other rigging components shall be attached in a secure manner.

• Hooks and other lifting attachments on the buckets of front-end loaders and backhoes are prohibited from use unless designed and certified by a professional engineer.

• Open hooks shall be used only when attaching or disconnecting the hook would place a worker in a dangerous position.

• A JHA must be used to establish the hazards and methods to protect against those hazards involved in the use of open hooks.

• Hooks shall be inspected for throat opening deformation prior to use.

Plate and Beam Clamps

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Document Number:

SCT-HSSE-SWP-4412



• Plate and beam clamps shall not be used for hoisting unless they cannot be practically replaced with another acceptable rigging component.

• If beam or plate clamps are used, they must meet the following requirements:

• Be locking or designed so that slackening of the hoist cable does not release the clamp

• Have manufacturer’s or professional engineer’s specification on capacity, sizes and methods of inspection, and upon request be available for audit on site.

Come-alongs, Chain Falls, and Lever Operated Wire Rope Winches (Tirfors)

• Come-alongs, Chain Falls, and Lever Operated Wire Rope Winches (Tirfors) used shall:

• Have the capacity identified

• Have all components including the hook, rated in consideration of the required safety factors and of a sufficient capacity for the hoist

• Not use the chain or cable to wrap around the load for hoisting

• If a come-along or other mechanical device is used to level a load, a safety sling, rated for the full load, must be secured above and below the come-along in case of failure

Design of Fabricated Rigging

• All rigging components such as links, spreader bars, equalizer beams, tailing beams, and attachments such as lugs, and trunnions, will be designed by a professional engineer to the more stringent of the following:

• Allowable Stress Design, American Institute of Steel Construction (AISC), Latest Edition.

• ANSI/ASME B30.20-2006, Below-the-Hook Lifting Devices. The maximum stress to be less than 1/3rd of yield strength.

• Alberta Occupational Health and Safety Act, Regulation and Code. The maximum stress to be less than 1/5th of the ultimate strength and 10% of the breaking strength of the weakest part of the rigging if a worker is being raised or lowered.

• Using an impact factor of 1.8 with AISC allowable stresses generally provides the minimum factor of safety required above by ANSI/ASME and OH&S.

• Pin holes shall meet the requirements of AISC Allowable Stress Design Section D3.2, Pin-connected Plates, with regard to minimum net areas.

• Any fabricated rigging such as spreader bars, links, lifting beams and other such equipment, must be designed and certified by a professional engineer prior to their use.

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Document Number:

SCT-HSSE-SWP-4412



• Fabricated rigging must have the identification number and SWL clearly and permanently attached.

5.5 Inspection, Testing and Certification of Rigging

Users shall conduct a visual inspection of rigging components prior to every use. Defective rigging shall not be used and will be removed immediately from service. All rigging components (including contractor-supplied components) shall be formally inspected annually and identified as being inspected within the past year. Rigging components shall not be used if the date of the last inspection is more than one year ago or if the last inspection date cannot be determined.

Spreader Bars, Lifting Beams, Links, and other Rigging Components

• All spreader bars, lifting beams, links, and other rigging components shall be:

• magnetic-particle or similarly inspected prior to first use on site either by vendor or by SCT site inspection

• visually inspected prior to each use and re-inspected (magnetic particle examination or similar) annually

Wire and Synthetic Slings

• All purchased wire slings must be proof loaded to two times the SWL by the manufacturer, prior to initial use.

• All slings must be numbered for reference and identified as to size and capacity.

5.5.2.1 Running wire ropes must be permanently removed from service if either of the following is observed:

• wear or corrosion that affects individual wires over more than one-third of the original diameter of the rope,

• evidence that the rope structure is distorted because of kinking, bird caging or any other form of damage,

• evidence of heat or arc damage, or

• normal rope diameter is reduced, from any cause, by more than.

• 0.4 mm if the normal rope diameter is 8 mm or less

• 1 mm if the normal rope diameter is > 8 mm and < 20 mm

• 2 mm if the normal rope diameter is > 20 mm and < 30 mm

• 3 mm if the normal rope diameter is 30 mm or more

5.5.2.2 Running wire ropes must be permanently removed from service if either of the following is observed:

• 6 or more randomly distributed wires are broken in one rope lay, or

• 3 or more wires are broken in one strand in one rope lay.

5.5.2.3 Stationary wire ropes such as guy lines must be permanently removed from service if either of the following is observed:

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Document Number:

SCT-HSSE-SWP-4412



• 3 or more wires are broken in one rope lay in sections between end connections, or

• more than one wire is broken within one rope lay of an end connection.

5.5.2.4 Wire rope that does not rotate because of its construction must be permanently removed from service if any of the following is observed:

• evidence of distortion due to kinking, bird-caging, or any other form of damage or evidence of heat or arc damage

• 2 randomly distributed wires are broken in 6 rope diameters, or

• 4 randomly distributed wires are broken in 30 rope diameters.

5.5.2.5 Synthetic (e.g., nylon, Kevlar®, or polyester) slings shall be removed from service if any of the following is observed:

• the length of the edge cut exceeds the web thickness

• the depth of an abrasion is more than 15% of the webbing thickness, taken as a proportion of all plies

• the total depth of the abrasion on both sides of the webbing is more than 15% of the webbing thickness, taken as a proportion of all plies;

• the depth of the warp thread damage is up to 50% of the webbing thickness and the damage is either: o within 25% of the sling width of the edge, or o covers 25% of the sling width

• the warp thread damage is as deep as the sling is thick either: o in an area that is within 25% of the sling width of the

edge, or o over an area that is more than 12.5% of the width

of the sling

• weft thread damage allows warp threads to separate over an area that is wider than 25% of the sling width and longer than twice the sling width

• part of the sling is melted, charred or damaged by chemicals

• stitches in load bearing splices are broken or worn

• end fittings are excessively pitted or corroded, cracked, distorted, or broken

• any internal wear indicators are visible

• sling is damaged in such a way that the total effect of the damage on the sling is approximately the same as the effect of kinking, bird-caging, or any other form of damage, including heat or arc damage

• Capacity tag is missing or illegible.

Shackles

• Shall be removed from service in case of any of the following:

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Document Number:

SCT-HSSE-SWP-4412



• no permanent indication of capacity from the manufacturer

• any cracks detected through magnetic particle examination or visual inspection

• any distortion to its shape

• a failure of the pin to fully seat into the body

• thread damage to a safety type shackle

Hooks


• evidence of cracks

• wear exceeding 10% of original dimension

• a bend or twist exceeding 10° from the plane of the unbent hook

• increase in throat opening exceeding 15% of original dimension

• missing or improperly functioning safety latch

Plate and Beam Clamps

• Shall be removed from service in case of either of the following:

• any failure or malfunction, or

• any evidence of cracks, damage or other defects

Come-alongs, Chain Falls, and Lever Operated Wire Rope Winches (Tirfors)


• any evidence of slipping or failure

• any evidence of cracks, damage or other defects on the body or handles

• excessive wear, stretch or deformity in the chain or cable

• capacity is not clearly visible

Certification

• All rigging must be re-inspected annually as required by the OH&S Code, or more frequently if specified by the manufacturer or Shell policy.

• Certifications for all fabricated lifting attachments (e.g., spreader beams, equalizer beams, and links) shall show the following:

• safe working load

• design calculations/drawings

• inspections performed

• intervals of re-inspection and required future inspection scope and methods

5.6 Lift Categories

Routine Lifts

• Routine lifting and hoisting operations are those performed with an identified low level of risk and complexity.

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Document Number:

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• Routine lifts are those carried out using standard lifting arrangements in ideal or normal weather conditions, with suitable laydown area and lifting of a stable load with a known and evaluated weight, shape and center of gravity.

• Center of gravity is below lifting point

• Lifts using standard rigging arrangements

• Answer 10 Questions for Safe Lifting and Hoisting (Appendix VIII)

Non-Routine Simple (Critical) Lifts

• All Non-Routine Simple (Critical) Lifts require the person in charge of planning the lift to complete and get approval of the Non-Routine Simple (Critical) Lift Planning and Authorization (Appendix IV). This authorization must be attached to the safe work permit (Permit).

• Any lift by mobile or fixed crane that includes any of the following conditions shall be treated as a Non-Routine Simple (Critical) Lift:

• Load and rigging exceeds 75%, but not more than 90%, of the crane’s capacity.

• Multiple cranes are required to make the lift, and at least one of the cranes will exceed 75% of its capacity.

• Lift is within 7 metres of overhead live high voltage (750 volts or more) power lines or within 360° of swing arc. This will also require an Overhead Power Line Encroachment Authorization. Refer to SWP SCT-HSSE-SWP-4416 for details.

• Any load weighing between 15 and 60 tons being off-loaded

• Any load weighing between 15 and 30 tons being set

• Blind lifts (a lift where at any point in time during the lifting operation the crane operator cannot see the load directly)

• Lifting of personnel

• Near/over active/energised hydrocarbon-containing equipment, overhead lines or underground lines


• On very complex lifts or lifts of a critical nature, Maintenance, Projects, Turnaround or Engineering may request an Engineered Lift study.

Non-Routine Complex (Engineered)

• All Non-Routine Complex (Engineered) lifts require the person in charge of planning the lift to ensure an Engineered Lift study has been completed and signed by a professional engineer having Shell ASME approval.

• As part of the Engineered Lift Study an Non-Routine Complex Lift (Engineered) check sheet, (Appendix V), must be completed.

• The Engineered Lift study document and the Non-Routine Complex (Engineered) Lift Check sheet must be attached to the Permit, prior to commencing the lift.

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• Any lift by mobile or fixed crane that includes any of the following conditions shall be treated as an Non-Routine Complex (Engineered) lift:

• lift in excess of 90% of the crane’s capacity

• any lift greater than 60 tons

• requires multiple cranes to make the lift and one or both cranes exceed 90% of their capacity

• Jack and Slide operations - unless the installation was designed for this type of lift.

• load with uncertain weight

• load with unknown or shifting center of gravity


• A Critical Task Analysis (CTA) must be conducted prior to performing all Non-Routine Complex (Engineered) Lifts.

• CTA will be arranged by the Shell Lead in charge of the job and will include the Shell ASME crane operator, rigger, signal person, Permit Issuer, and all others who are directly involved in the lift.

5.7 Working in Close Proximity to Suspended Loads

The following are typical situations where personnel may work in close proximity to a suspended load:

• Rigger or craftsperson attending the tag line for setting equipment or skid pans into the proper position, and

• Catalyst loading, e.g., super sacks Do not make lifts over personnel.

• Verify that the suspended load path is clear of obstacles and personnel when making a lift. Refer to Appendix III for details.

If access under a suspended load is required, secure the load by setting it on cribbage or blocking.

In the rare case that walking or working directly under a suspended load is required a deviation from LSR #7 must be approved in writing by the HSSE Manager.

When lifts occur, the following protocol shall be applied:

• Red flag-off the areas where the suspended load is being lifted, or reasonably could fall if failure were to occur, to prevent personnel unrelated to the work from traversing through the exposed lift area.

• When lifts are made, the crane operator or spotter shall use a horn or whistle to alert nearby personnel.

• During the lift, personnel inside the red flagged-off area shall be limited to those directly related to the task or lift at hand.

• Always use tag lines to assist in setting or guiding the load.

• Crane operator shall maintain radio contact with the rigger at all times during the lift, if view of hand signals is obstructed.

5.8 Crane Suspended Personnel Baskets

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This section establishes the minimum standard for safe design, use, inspection and testing of crane suspended personnel baskets. CSA Standard CAN/CSA-Z150-11, Safety Code on Mobile Cranes shall be used as the reference for lifting personnel baskets. A CTA must be conducted prior to performing all crane suspended personnel basket lifts. The CTA will be arranged by a Shell Supervisor in charge of the job and will include the Shell ASME crane operator, rigger, signal person, Permit Issuer, and all others who are directly involved in the lift.

General Requirements

• Personnel baskets shall only be used when other methods of access are not practical, would create a greater hazard, or are not possible due to structural design or site conditions.

• Use of a personnel basket shall require approval of the Crane-Suspended Personnel Basket Authorization (Appendix VI) by the Shell Job Owner. The lift calculation for the personnel basket shall be used for this purpose and shall be attached to the Permit.

• Personnel shall keep all parts of their bodies inside the personnel basket during raising, lowering and positioning, and may not exit the basket at any time while the basket is elevated, even if the basket is secured to a structure. Note: The personnel basket must be landed on a suitably designed structure prior to exiting the basket.

• Tag lines shall be used for all lifts, unless their use will create a hazard.

• Hoisting of personnel shall be stopped upon indication of any dangerous weather conditions or other impending hazards.

• Personnel occupying the personnel basket shall wear a safety harness with the lanyard attached to an engineered tie-off point within the basket.

• Personnel baskets designed specifically for lifting people shall not be used as a material hoist.

Trial Lift

5.8.2.1 A trial lift shall be performed to verify the integrity of the rigging and the personnel basket and to ensure all systems, controls, crane set-ups, lift routes and safety devices are

activated and functioning properly for each location where the personnel basket will be lifted and positioned.

5.8.2.2 The trial lift shall ensure no interference exists and all configurations necessary to reach work locations will allow

the operator to remain under the 50% limit of the crane’s rated load capacity.

5.8.2.3 The trial lifts shall be suspended by the primary support (with the secondary support attached above the ball) and lift the

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personnel basket (with the test weight attached) to all work locations.

5.8.2.4 After the trial lift and just prior to hoisting personnel, the personnel basket shall be hoisted a few inches and inspected to ensure it is secure and properly balanced.

• Personnel shall not be hoisted unless both of the following conditions are met: o Hoist ropes are free of kinks o Primary attachment is centred over the personnel

basket

• The hoisting system shall be inspected if the load rope is slack to ensure all ropes are properly stated on drums and in sheaves.

5.8.2.5 A visual inspection of the crane, rigging, personnel basket, and crane base support or ground shall be conducted by a

competent person (i.e., the rigger) immediately after the trial lift to determine whether the testing has exposed any defect

or produced any adverse effect on any component or structure.

5.8.2.6 Any defects found during inspections that create a safety hazard shall be corrected before hoisting personnel.

5.8.2.7 Test weights must be removed before hoisting any personnel in the personnel basket.

Design of Personnel Baskets

5.8.3.1 A professional engineer competent in structural design shall design personnel baskets.

5.8.3.2 The personnel basket will be designed and constructed for the specific purpose of hoisting personnel by means of a crane.

5.8.3.3 The personnel basket shall be of welded construction with a design safety factor of 10.

5.8.3.4 A drawing showing the serial number, total weight, maximum number of persons allowed, maximum weight capacity and

safety factor used for calculations shall be provided for all personnel baskets.

5.8.3.5 The following items shall be considered for personnel baskets designed specifically for lifting people:

• Lifting bridles on the personnel basket shall be designed to minimize tipping of the personnel basket due to movement of personnel in the personnel basket

• Include a 1.07metres (42”) high guard-rail for perimeter protection of personnel within the personnel basket

• The personnel basket shall be closed on all sides below the handrails, with solid material or expanded metal with openings no greater than 12 mm (1/2”)

• The floor shall be of solid material

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• An attachment point for the personnel basket safety line from above the ball separate from the primary suspension attachment, as well as attachments for lanyard safety hooks on fall arrest equipment, shall be included in the design

• Gates shall swing inwards and be equipped with a positive locking device

• A welder qualified for the weld grades, types and material specified in the design, shall perform all welding

• All exposed rough edges shall be ground smooth

• All surfaces shall be painted to protect against corrosion, preferably with high visibility paint

• A permanently attached plate noting the serial number, total weight of the personnel basket, maximum number of persons allowed, and maximum capacity shall be attached to the personnel basket in a prominent location

Mobile Crane Set-up and Operation

5.8.4.1 The mobile crane shall be level within 1 degree and located on firm footing.

• Outrigger pads shall be used on all hydraulic and truck mounts.

• Crane travel is prohibited while personnel are suspended in the personnel basket.

• The crane operator shall remain at the controls at all times, with the engine running, while personnel are suspended in the personnel basket.

5.8.4.2 The total weight of the loaded personnel basket and related rigging shall not exceed 50% of the rated capacity for the radius and configuration of the crane.

• Hoisting and lowering speeds shall not exceed 30 metres (100 feet) per minute.

• The load line shall have controlled (power) load lowering capability; free fall is prohibited.

• The crane’s braking systems shall be equipped such that an engine failure will result in automatic engagement.

5.8.4.3 All cranes and hoists used for hoisting personnel shall have a load-monitoring device to verify lift weights.

• Cranes shall also have an anti-two block device to warn the operator of two-block situations.

5.8.4.4 Persons being hoisted shall be in continuous sight of or in radio communication with the crane operator.

• If at any time the crane operator cannot see hand signals or hear radio communications, the operation shall be stopped until signals can be received.

5.8.4.5 Load and boom hoist drum brakes, swing brakes, and locking devices such as dogs and pawls, as equipped, shall

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be engaged when the occupied personnel basket is in a stationary position.

Rigging

5.8.5.1 All rigging used for hoisting personnel shall comply with the requirements for rigging design, use, inspection, and testing.

5.8.5.2 Load block or ball hooks shall be of a type that can be locked and closed to eliminate the throat opening and the potential for rollout.

• As an alternative a shackle may be used.

5.8.5.3 Any shackles used as a rigging attachment for hoisting personnel must be of the type with screw pin, nut and

retaining pin, or have the screw pin wired to prevent it from turning.

5.8.5.4 All eyes in wire rope slings shall be fabricated with thimbles.

5.8.5.5 Wire rope and other rigging hardware used for hoisting personnel shall have a minimum safety factor of 10 to 1.

5.8.5.6 Rigging components used for hoisting personnel shall not be used for any other purpose.

5.8.5.7 A safety wire rope sling capable of withstanding the entire weight shall be attached to the personnel basket, at a separate location from the primary point of suspension.

• The other end of the safety line shall be attached above the ball or above the hook on the block.

5.8.5.8 When used for hoisting personnel, and if equipped with a secondary hoist line, the line and rigging on a hydraulic crane shall be removed, or set in such a way that it will not tangle

or endanger personnel on the platform or prevent safe operation of the crane.

Inspection and Testing

5.8.6.1 All personnel baskets shall receive a professional engineer’s certification once a year to the specifications for inspection, maintenance, and repair.

5.8.6.2 The crane, personnel basket, and associated rigging shall be inspected by a competent person at the beginning of each shift before hoisting personnel.

5.8.6.3 A trial lift with the personnel basket unoccupied shall be made for each new work location and at the beginning of

each shift to ensure there are no obstructions and all system controls and safety devices are functioning properly.

5.8.6.4 A visual inspection of the crane, personnel basket, associated rigging, and base support shall be done after the trial lift to determine any adverse effect on the components.

• Any defects found shall be corrected before further use of the personnel basket.

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Pre-lift Meeting/CTA Review

• A meeting attended by the crane operator, signal person, and Shell Supervisor responsible for the job shall be held to review the Crane-Suspended Personnel Basket Authorization (Appendix VI) and the CTA and ensure everything is prepared for the lift.

5.9 Tag and Hoisting Lines

If workers are in danger because of the movement of a load being lifted, lowered or moved by a lifting device, an employer must ensure that:

• a worker uses a tag line of sufficient length to control the load,

• the tag line is used in a way that prevents the load from striking the worker controlling the tag line, and

• a tag line is used when it allows worker separation from the load. An employer must ensure that tag lines of non-conductive synthetic

rope are used when there is a danger of contact with energized electrical equipment.

An employer must ensure that tag lines are not used in situations where their use could increase the danger to workers.

References

6.1 Alberta – Occupational Health and Safety Code, July 1, 2009, Part 6,

Cranes, Hoists and Lifting Devices, Sections 59-114

6.2 CSA Standard CAN/CSA-Z150-11, Safety Code on Mobile Cranes

6.3 Shell HSSE & SP Control Framework, Life-Saving Rules,

6.4 DEP 60.00.10.13, Mobile Crane Foundation Assessment

6.5 DSOS HSSE Standard 10.11, Mechanical Lifting and Hoisting

6.6 DSM RP-01, Working/Walking Under Suspended Loads

6.7 O.T.I.S. Maintenance Procedure “Crane and Bridge Signage”

6.8 Construction Safety Association of Ontario “Crane Handbook”

6.9 Safe Work Practice SCT-HSSE-SWP-4416, Work in Proximity to Overhead

Power Lines

Implementation

Managers and Team Leaders shall ensure implementation of this safe work practice within their areas of accountability.

Interpretation and Updating

The Scotford HSSE Manager shall ensure interpretation and updating of this safe work practice.

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Glossary of Terms

Boom Fall Radius – The distance from the centre of the crane to the tip of the boom (boom fully down). Pedestal cranes must include the height of the pedestal Competent – Per OH&S Code, “competent” in relation to a person, means adequately qualified, suitably trained and with sufficient experience to safely perform work without supervision or with only a minimal degree of supervision. DEP – A Shell Design Engineering Practice. Load Path – The path that the suspended load will travel over ground. This area includes the ground directly under the load and the area that the load will travel over to its final resting point. Off Loading – A load being removed from the bed of a truck or trailer. PIC – Person In Charge Radius – The distance from the crane’s centre of rotation to the centre of gravity of the load being picked. Setting – a load being positioned into its final location. Shell ASME- Accredited Subject Matter Expert Two Blocking – When the load block comes into contact with the tip of the boom or boom sheave.

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Lift Review Flowchart

INITIAL REVIEW

OF LIFT

1. Load has shifting

centre of gravity.

2. Lift is within 7 m of

live high voltage

conductors or within

360 degrees of swing

arc.

3. Load and rigging

exceeds 75% of

crane’s capacity.

4. Load being

offloaded is 15 to 60

tons.

5. Load being set is 15

to 30 tons.

6. Multiple crane lift

with one at > 75%

crane capacity.

Multiple cranes

and load > 90% of

either crane’s

capacity

Crane capacity

> 90%

Load > 15 tons

Crane capacity

> 75%

Offload or

Setting

Load > 60 tons

Load > 30 tons

Proper Trade

Practice

Engineered Lift

Study

Critical Lift Form

YES

NO

NO

OFFLOAD

SET

YES

NO

YES

NO

NO

YES

YES

YES

NO

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SCT-HSSE-SWP-4412



Interpretation and Clarification of LSR # 7

DO NOT WALK UNDER A SUSPENDED LOAD 1. Definitions

This section defines the terms used in the clarification of LSR # 7.

Arc – The circular path that the suspended load makes over the ground area. This area encompasses the maximum circular travel of the boom with a load, with the crane base as the centre point.

Crane

Exposed Lift Area – The area within the working arc of the boom extending from the centre of the crane to the end of the boom, including the outer edge of any suspended load. This is the area that the suspended load may be lifted over at any time. The area may be pie-shaped and will vary according to load and boom angle.

Crane

Load Path – This area includes the area directly under the load initially and the area that the load will travel over to its final resting point.

Arc Top View

Exposed Lift Area Area

Top View

Crane Side View

Structure/pipe rack Lower level on structure is considered unexposed area. See definitions below.

Exposed Lift Area

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APPENDIX III (continued)

Load Radius – The horizontal distance from the centre of the crane to the centre of a suspended load.

Suspended Load – All rigging (except nylon or Kevlar® slings) and load that is suspended on the crane hook and is not secured by setting the load on cribbage or blocking. The boom and hook are not considered part of the suspended load.

Unexposed Area – Any area that is not under a suspended load. This area will also include lower levels on structures over which a load or boom may pass and provides overhead protection to workers in the area. The unexposed area will depend on the weight of the load and the protection offered by the overhead structure.

2. Parked/Standby Cranes

Workers can walk under a parked lifting boom and hook provided that the lifting equipment is locked out and secured in accordance with manufacturer's specifications. No worker shall enter any portable building/trailer within the boom fall radius while the crane is parked.

3. Exceptions

• Personnel baskets suspended from the hook are not considered to be working under a load.

• JLGs are out of scope.

• Carry deck cranes are considered cranes. The exemption is for the operator of a carry deck to allow the boom to swing over the cab of the carry deck only when no other positioning options are available. This activity shall be identified on the JHA/FLRA.

• A worker is not considered to be working under a load when he/she reaches out to grab a tag line that is attached to the side of a load if the worker's body is not under the suspended load.

Crane

Load Radius

Side View

Boom

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Non-Routine Simple (Critical) Lift Planning and Authorization

SCT-HSSE-4412-F-1.docx

Double click on the icon to open the Authorization in Word.

Non-Routine Complex Lift (Engineered) Checklist


Double click on the icon to open the check sheet in Word.

Crane-Suspended Personnel Basket Authorization


Double click on the icon to open the Authorization in Word

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Document Number:

SCT-HSSE-SWP-4412



Lift Categorization Example

Lift Categorization

v12.pptx

Double click on the icon to open the Authorization in PowerPoint

10 Questions for Safe Lifting and Hoisting

10 Questions.docx


Lift Planning Template

Lift Planning

V04.docx


Documents

Scotford Safe Work Practice