Lifting and Mechanical Handling Guidelines

p l a n n in g o f l if t in g o p e r a t io n s responsible person

Identify lifting activity. Notify or appoint a Competent Person

competent person

competent lif t in g t e a m

technical support t f i l e h t e n i f e d

Determine scope of work

Assess risks and produce lift plan

Provide technical supp ort as required

The plan and the Task Risk Assessment may be existing, modified or new

t f i l e h t n a l p

Finalise lift plan

Ensure all equipment suitable for intended use

May be involved as required

Appoint competent p ersonnel


Conduct toolbox talk, review plan and Task Risk Assessment

Participate in toolbox talk



Carry out lift wit h appropriate supervision as required

Conduct post job debrief, note learning points

Retain plan, Task Risk Assessment and lessons learned

t f i l e h t m r o f r e p

d r o c e r d n a n r a e l

contents

Preface 1

H o w t o U s e t h is D o c u m e n t

2

I n t r o d u c t io n

3

R e s p o n s ib ilit ie s

4

5

3 .1

Responsible Person

3 .2

Competent Person

3 .3

Competent Lifting Team

3 .4

Technical Support

T h e L if t 4 .1

Define the Lift

4 .2

Plan the Lift

4 .3

Perform the Lift

4 .4

Learn and Record

Tr a in in g a n d C o m p e t e n c y 5 .1

Personnel Undertaking Lifting and Mechanical Handling Operations

5 .2

Personnel who Plan and Supervise Lifting Operations

6

S um m a ry

7

A p p e n d ic e s

L IF T I N G & M E C H A N I C A L H A N D L IN G G U I D E LI N E S

1 h o w t o u s e t h is d o c u m e n t In compiling these Lifting and Mechanical Handling G u i d e l in e s , i t w a s r e c o g n is e d t h a t m a n y o r g a n is a t io n s already have processes and procedures that work well. With this in mind, they are designed to provide guidance in two ways: 1. To ena ble you to a ss ess your current wo rking method s ag ainst the principles put forwa rd here a nd s o help you identify improvements to thos e methods in line with current best practice. 2 . To a llo w y o u t o a d o p t i mp ro v e d m e t h o d s f o r lifting and mechanical handling operations, based on current best practice.

This document puts forward a model for planning lifting and mechanical handling operations, similar to many used in our industry already. This model, illustrated inside the front cover, has been designed to b e p r a c t ic a l a n d e a s y t o u s e . Information on the responsibilities of those involved in lifting and mechanical handling operations is given , as well

as

a

definition

of

minimum

standards

of

competency for carrying out such work. Definitions of key terms are included at the end of the document. Each company shall ensure that all personnel involved in lifting and mechanical handling operations clear ly understand their responsibilities. When deficiencies in training and competency have been highlighted, it is t h e d u t y o f t h e e m p l o y e r to t a k e a p p r o p r ia t e a c t io n t o address the situation.

L IF TI N G & M E C H A N I C A L H A N D L IN G G U I D E L I N E S

1

2 introduction Because of their hazardous nature, lifting and

T h e s e c o m p o n e n t s a re :

mechanical handling activities can and do result in serious

harm

to

personnel,

damage

to

plant,

•

Th e p la n n in g o f t h e lif tin g o p e r a t io n w i t h th e

equipment or the environment, and business loss.

development a nd implementa tion of a

This

documented lift plan

document

describes

the

key

components

necessary to ensure that such activities are carried out safely, and in compliance with UK legislation such as The

Lifting

Operations

and

Lifting

•

S u it a b le a n d a d e q u a t e a s s e s s m e nt o f t he ris ks a ss ociated with the lifting operation

Equipment

Regulations (LOLER). It also helps in meeting the requireme nts of othe r relevant regulations including the

•

C o r re c t s e le c t io n a n d us e o f a p p ro p ria t e equipment

M a n a g e m e n t o f H e a lt h a n d S a f e ty a t W o r k R e g u l a tio n s (MHSWR) and the Provision and Use of Work E q u i p m e n t R e g u la t io n s (P U W E R ).

•

U s e o f e q u ip m e nt w h ic h is m a in ta in e d a n d in good condition

•

C l a rit y o n t he ro le s , r e s p o n s ib ilit ie s a n d w h o i s in control of the lifting operation

•

In vo lv e me n t o f s u it a b ly t ra in e d a n d experienced personnel who ha ve been a s s e s s e d a s c o m p e t e nt

•

Ma in te na n c e o f d a t a b a s e s o f a p p ro ve d ris k assessments and lift plans

•

2

Im p le m en tin g le s s o ns le a rn ed .


3 responsibilities Everyone involved in lifting and mechanical handlin g operations has specific responsibilities. These are defined in the following paragraphs:

3 . 1 R e s p o n s i b le P e r s o n

3 . 3 C o m p e t e n t L if t in g T e a m

Th e R e s p o n s i b l e P e r s o n i s t h e p e r s o n w h o h a s

E a c h t e a m m e m b e r h a s t h e r e s p o n s i b i lit y to k n o w a n d

overall responsibility for work activities. This person

work within their own competency to complete the

may be the Shift Supervisor, Base Manager, Project

jo b . Th e y a re re q u ire d to a tt e n d an d p a rt ic ip a te in

Engineer or Toolpusher, for example. The Responsibl e

toolbox talks, carry out pre-use inspections of lifting

Person recognises, or is advised of, the need for a

equipment and stop any operation when they are

lifting ac tivity and either no tifies the C om pe tent Perso n

c o n c e r n e d a b o u t it s s a f e ty .

or appoints a Competent Person to plan the lifting operation.

3 . 4 Te c h n ic a l S u p p o r t

3 .2 C o m p e t e n t P e r so n

Those providing technical support must be technically competent in the area of expertise upon which they

Th e C o m p e t e n t P e r s o n i s s o m e o n e w h o h a s t h e

a r e re q u e s t e d t o a d v i s e .

required level of competency to plan and supervise lifting operations. He must have the practical skills, theoretical knowledge and ability to carry out risk assessments, produce and assess lift plans and c o n d u c t t o o lb o x t a lk s . T h e C o m p e t e n t P e rs o n m a y o r may not supervise the lifting operation but is the focal point of authority for the technical aspects of the lift. He must know his competency limitations, work within them and know when technical support is needed. The level of competency required to perform this role is i n c lu d e d i n S e c t io n 5 o f t h is d o c u m e n t . The Competent Person is responsible for appointing t h e te a m t o c o m p l e t e a lif t. H e m u s t e n s u r e th a t th e team members have the competencies to complete t h e j o b a n d t h e t a s k s e n t a ile d .

L IF TI N G & M E C H A N I C A L H A N D L IN G G U I D E LI N E S

3

4 t h e lif t 4 .1

D e f in e t h e L if t

Identify Lifting Activity T h e R e s p o n s i b le P e r s o n s h o u l d i d e n t if y o r b e i n f o rm e d of the need for a lifting operation and inform the Competent Person or appoint a Competent Person. The Competent Person will plan and, if appropriate, sup ervise the lifting op eration .

Determine Scope of Work The Competent Person must begin his planning process by determining the scope of work – defining w h a t is t o b e d o n e , w h o s h o u l d b e i n v o lv e d , h o w it w i ll be conducted. This may require an initial lift plan, sketches, notes etc. If additional technical support is r e q u i re d , i t s h o u ld b e o b t a in e d b e f o r e p r o c e e d i n g .

4 .2

Lift Plans

P la n t h e L if t

The lift plan is intended to clearly identify the

Task Risk Assessment

Competent Person planning the lift, the lifting

Every lifting operation will be risk assessed by the

operation to which it relates, step-by-step instructions

Competent Person before the work begins. The

for carrying out the lift, the equipment required, and

Competent

appropriate

the activity assigned to each person. Many employers

controls are in place for those hazards identified in the

have systems in place to enable the lifting operation to

written risk assessment such that the risks are

be classified as ‘routine’ or ‘non-routine’. For routine

managed as an integral part of the lift plan. A suitable

lifts, the lift plan may be ‘generic’ in nature but will still be

documented risk assessment may already exist for

reviewed prior to each lift, or before a series of similar

‘routine’ lifts. If so, the existing risk assessment must

lifts. For ‘non-routine’ lifts, this may be further classified,

be reviewed for its applicability. If any significant

for example in terms of simple, complicated and

c h a n g e s a r e r e q u i re d t o t h e e x i s t in g r is k a s s e s s m e n t ,

complex. The classification of lifting operations is

for example there are additional risks not accounted

designed to give the Responsible Person and

f o r, a n e w r is k a s s e s s m e n t m u s t b e

Competent Person additional guidance in terms of the

produced.

risk assessment, planning, supervision and the

Person

will

ensure

that

c o m p e t e n c e r e q u ir e m e n t s o f t h e p e r s o n n e l p e r fo r m i n g the lifting operation. An example of a R i s k M a t r i x is given in the A p p e n d i c e s . T R A f o r m s are available fro m the Step Change in Safety Task Risk Assessment Guid e.

4

The nominated Competent Person will approve every lift plan. A n e x a m p l e lif t p la n i s in c l u d e d in t h e A p p e n d ic e s .


4 t h e lif t Ana lys is of rec ent lifting-rela ted fata lities in the North Sea has identified a common fa ctor

•

The pla ce w here it w ill be us ed

•

The c ond itions unde r which it will be us ed

•

The purpos e for w hic h it w ill be us ed

•

Inherent risks to hea lth and sa fety as a res ult of

where perso nnel mista kenly c onsider that a ‘ routine ’ lifting operation is therefore a ‘ s a f e ’

lifting operation. A review w ith reg a rd to the c ontinued

its us e

a pplic a bility of the Ta sk Risk As se s sm ent a nd Lift P la n for these ‘ routine ’ lifting operations must be c arried o ut and these must b e disc uss ed a t the Too lbo x Ta lk.

Technical Support In the planning stage of the lifting operation, the re will be occasions when the Competent Person identifies the need for additional technical support. A technical authority review is undertaken by someone who has t h e n e c e s s a r y c o m p e t e n c ie s t o m a k e a n in f o rm e d a n d impartial judgement on the lift plan. This may range f ro m a n o t h e r C o m p e t e n t P e r s o n r e vie w i n g t h e lif t p la n to the involvement of a structural engineer to check t h e lo a d in g s o n b e a m s o r la y d o w n a r e a s . It is i m p o r t a n t th a t t h o s e a c t in g a s C o m p e t e n t P e r s o n s acknowledge that there will be limits to their expertise and that they are aware of the personnel available to p r o v id e t h e m w i t h te c h n ic a l s u p p o r t w h e n r e q u i re d .

Finalise Lift Plan After completion of the risk assessment, the lift plan must be checked to ensure that all the hazards identified in the risk assessment have been managed throug h the c ontrol me asures d etailed in the lift plan.

Selection of Lifting Equipment

Ergo nomic ris ks

•

Manual handling.

The lifting equipment provider must ensure that all lifting equipment and lifting accessories are subjected to a thorough examination scheme and in-service in s p e c t i o n s t o e n s u r e c o n t in u e d in t e g r it y . T h e u s e o f a colour code system to identify examined equipment is recommended.

Selecting Competent Personnel O n ly s u i ta b l y C o m p e t e n t P e r s o n n e l s h o u ld b e in v o lv e d in lifting operations. Personnel should be trained, assessed and monitored as part of a Competency Scheme. Section 5 details the competency standards expected of p ersonn el involved in lifting op erations in the various sec tors of the oil and gas industry. There are a multiplicity of different types of lifting operations onshore/offshore, on platforms or floating vessels, using various types of lifting equipment, with a wide range of items to be lifted. It would be im prac tica l to de velop g uidanc e for every spe cific lift.

Personnel in a lifting team, especially the

The Competent Person will have identified the appropriate lifting equipment and accessories required. It is essential that the equipment being used is certified , fit-for-p urpo se an d visually ch ec ked for any defects etc before being used. The Competent P e r s o n m u s t t a k e i n to c o n s i d e r a tio n : •

•

The tec hnica l sp ec ifica tion a nd integrity of

person in charge of a lifting operation, must a lwa ys bea r in mind tha t if they co nsider that the operation exceed s their level of co mpetenc y, they must s top the operation until a suita bly Co mpetent P erson is a ble to as sist or ta ke over.

eq uipment (P UWER Ass es sme nt)


5

4 t h e lif t

Other interested parties should not bring pressure to bear on personnel performing lifting ope rations.

Although the person in control of the lifting operation is responsible for ensuring the lifting operation is carried out in a safe manner, all personnel involved also have a resp on sibility for ens uring that the lift is c arried ou t safely.

The C omp etent P erso n, whe n pla nning the lift, must ens ure that the s elec ted perso nnel have experience of, a nd demo nstrated competency in, the sa fe use a nd ope ration of the eq uipment a nd tec hniq ues req uired to perform the lifting ope ration.

4 . 3 P e r f o r m t h e L if t

Conducting the Review and Toolbox Talk

Lifting Operation

Once the lift plan has been approved, the Competent

The lifting operation will be conducted following the

Person will hold a toolbox talk with all the appointed

agreed and approved lift plan, using current and

personnel involved in carrying out the lift. At the

industry best practice. Many operators and lifting

toolbox talk, individual responsibilities will be allocated

contractors publish their own guidance documents on

including identification of who will be in control of the

lifting techniques, equipment specifications, pre and

lifting operation. During the toolbox talk, all personnel

post-use inspection checksheets etc and these

will review the findings of the risk assessment and the

should be referenced.

lift plan, and discuss these step-by-step to ensure t h a t e v e ry o n e c le a r ly u n d e r s ta n d s a n d a g r e e s w it h t h e m e t h o d s a n d c o n t ro l m e a s u re s t o b e u s e d .

It is important that lifting equipment is only used in accordance

with

the

manufacturers’

operating

in s t r u c t io n s a n d r e fe r e n c e s h o u ld b e m a d e t o t h e m . If, after discussion, there is an agreed change to the risk assessment and/or lift plan, the Competent Person will amend the documentation and seek

Everyone involved in the lift ha s the

re-approval.

respo nsibility to s top the lifting o pera tion a t

Example Prompt Cards providing guidance on

any time if they believe the operation could, or has , bec ome unsafe or there is a cha nge from

planning and performing lifts and Toolbox Talk Forms are included in the Append ices.

6


the ag reed plan.

4 t h e lif t For additional useful guidanc e, refer to the Step Change in Safety Look This Way Safety Observat ion Systems guidance booklet.

A safety observation programme provides a means of encouraging safety observations and prompting individuals in recognising unsafe acts and unsafe conditions. The following 9 ‘Steps to Safety’ identify the key elements of such a programme:

1. Decide

7. What can go wrong?

Decide to carry out the observation, gather any relevant information on the area or task.

The discussion should foc us on what w as observed to b e unsafe. Use open questions to involve the person and allow them to state the unsafe be haviour so they ‘own’ it. Explore the co nsequences and try to get the person to see all the effects on the p erson, team, fam ily etc.

2. Observe Use all your senses d uring the ob servation and be prepared to intervene or stop the job, if needed.

8. Why unsafe behaviour?

3. Introduction Introdu ce yourself, put p eop le at ease. If you already know the p erson, this may be mo re informal.

4. Explain Explain that you are c arrying out a safety observation and the benefits to them and the team (eg to acknow ledge safe behaviours and to disc uss any safety improvem ents).

5. What is the job? Use open questions to start a discussion on what the person is doing.

6. Praise ALWAYS start w ith safe b ehaviours. Building on mo tivational feedback encourages openness and c ommunication. Give specific examples and say wh y they are important to reinforce safe behaviours. State sincerely what you want to say. Be honest but do no t patronise.

Explore the reaso ns for the un safe beh aviour. Look for the causes and then the root causes.

9. What corrective action is needed? See if they have any ideas on ho w to do the job or task mo re safe ly. Ge t the m to offer the solutions. Get agreement on c hanges to be made. Rec ord the observation.

4 .4 Le a r n a n d R e c o r d

Post J ob Debrief and Learning Points After completing the lifting operation, everyone involved in the lift has the opportunity to discuss and make improvements to the lift plan. Any learning points noted on the plan will be reviewed by the Competent Person and actioned, as appropriate. For example, this

may

include

feedback

on

equipment

effectiveness, lifting techniques, etc. Companies should ensure that the significant learni ngs and improvements identified from lifting operations are r e c o r d e d a n d c o m m u n i c a t e d t o a l l r e le v a n t p a r tie s .


7

5 t r a i n in g a n d c o m p e t e n c y All personnel involved in lifting and mechanical handling operations should be trained, have the required experience for the type of lift to be u n d e r ta k e n , a n d b e f o r m a l ly a s s e s s e d a s c o m p e t e n t .

5 .1 P e r s o n n e l U n d e r t a k in g L if t in g a n d M e c h a n ic a l H a n d l in g O p e r a t io n s The diagram on page 9 shows the four key stages that an individual has to pass through to reach full competency. The chart on page 10 identifies the categories of personnel who undertake lifting and mechanical handling operations and the suggested training and competence

assessment

for

these

groups

of

personnel. There are a number of training courses available, some of which are based upon and meet industry occupational

standards

developed

by

training

s t a n d a r d s o r g a n i s a tio n s s u c h a s C o g e n t .

8


5 t r a i n in g a n d c o m p e t e n c y mechanical handling competencies will differ across the industry. For example, lifting operations carried out

Stage 1 Onshore Initial Training and Assessment

Stage 4 Ongoing Performance Development

by drilling co ntractors m ay involve d ifferent s kills from those carried out by construction or marine

AUDIT PROCESS

contractors.

Stage 2 Supervised Workplace Training

In the case of non-core personnel employed on short-term contracts, employers must have a system in operation to validate the competency o f t h e s e p e r s o n n e l a n d , i f n e c e s s a r y, u p d a t e a n d refresh

Stage 3 Workplace Assessment

the

skills

and

knowledge

of

such

personnel. If drilling personnel are performing lifting operations which are not covered by the Offshore Drilling Operations Standards then additional competencies will be necessary. This could be the case on Mobile Drilling

Units

where

the

services

of

personnel

c o m p e t e n t i n r ig g i n g a n d lif tin g o p e r a tio n s m a y n o t b e

Four Key Stages in Achieving Competency

available. In this case, the Introduction to Rigging and The first stage of all training comprises initial training

Lifting Operations Standard will be appropriate

and assessment. This is normally carried out at an

f o llo w e d b y w o r k p la c e t r a in in g a n d a s s e s s m e n t .

onshore training establishment – in t h e c h a r t s h o w n o n page 10 this is identified as Stage 1. At the

There

completion of Stage 1, the level of competency is

competent to undertake lifting and mechanical

deemed sufficient for that person to conduct lifting

handling operations are required to use equipment

operations

such as overhead cranes and air tuggers. This

under

the

direct

supervision

of

a

will

also

be

occasions

when

personnel

equipment is generally not addressed in training

c o m p e t e n t p e r s o n a s p a r t o f t h e ir S t a g e 2 t ra in in g .

courses. Therefore in such circumstances, personnel Stage 2 is supervised training and the practical

should make themselves familiar with the equipment

application of the learning obtained in Stage 1.

manufacturers’ instructions and relevant standards p r io r t o u s e o r m a i n te n a n c e .

Stage 3 is the workplace assessment of competency with

Stage

4

as

the

ongoing

performance

development.

The Training and Competency requirements identified in this document are meant to be rigorous but not limiting. Persons trained to other, equivalent standards

In order to conduct safe lifting operations to today ’s high standards, it is important that employers have a

m a y a ls o b e d e e m e d c o m p e t e n t .

system in operation which permits personnel to p r o g r e s s th ro u g h t h e s t a g e s t o b e c o m e c o m p e t e n t to undertake lifting operations and to maintain this competence.

It

is

recognised

that

lifting

and


9

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o R

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s ) r n d o t d o a i d t n n a t - n o a r n a i t g e e t c i p g S u n O o d d g e v g g C o ( o i r n t R r i t p n f I i p L a

d r a d n a t S y r t s u d n I d e s i n g o c e R

e g a t S

e c a l p k r o W

4

e g a t S

e c a l p k r o W

3

e g a t S

e c a l p k r o W

2


e r o h s n O

1

e g a t S

t

g g n n i i n e k s a u m t r s l e p e n i d o b i u n t a q u r t l a r E e e o n p n o P g o g i n s n t r t f e i f P i l i L

t e n . y t e f a s n i e g n a h c p e t s . w w w

: e t i s b e w y t e f a S n i e g n a h C p e t S e h t o t r e f e r e s a e l p m a r g a i d s i h t f o n o i s r e v t s e t a l e h t r o F

5 t r a i n in g a n d c o m p e t e n c y 5 .2 P e r s o n n e l w h o P l a n a n d S u p e r v is e L if t in g O p e r a t io n s T h e C o m p e t e n t P e r s o n e g R i g g e r, R ig g i n g S u p e r v is o r, LOLER Focal Point, Crane Operator, Toolpusher, Barge Engineer or Maintenance Supervisor should normally have at least 3 years’ operational experience of lifting operations before undertaking the role o f the Competent Person. The formal training prior to the m in im u m o f 3 y e a r s ’ o p e r a t io n a l e x p e r ie n c e s h o u ld b e e q u i v a le n t t o t h a t d e f in e d in S t a g e s 1 t o 3 . T h e y m u s t have experience in producing lift plans and should undertake further training in advanced rigging and lifting, w here ap prop riate.


11

6 summary There

are

many

examples

of

robust

and

fully

operational systems for carrying out lifting and mechanical handling operations. Regardless of the s y s t e m u s e d , t h e im p o r ta n t f a c t o rs a r e : •

Th e lif t is p r o p e rly d e f in e d

•

R e s po n s ib le a n d C o m p e te nt P e rs o n ne l a re a ppo inted to plan the lift

•

Th e c o m p e te n c y o f th e p e rs o n n el c a r ry in g o u t the work should be sufficient for the task to be undertaken

•

Th e lif t is p la n n e d t o e n s u re t h a t a ll h a z a rd s have b een identified, risks ma nag ed a nd ap propriate mea sures taken to c ontrol these risks

•

To ensure that the lift is ca rried o ut with suitab le eq uipment, in acc ordanc e w ith a we ll-defined plan

•

To e n s u re t h a t t h e c o n d i tio n s f o r t h e p la n a re forese en and that if the cond itions c hang e, the hazards, risks and controls are reassessed

•

To e n s u re t h a t le s s o n s le a r n e d a r e ta k e n in t o account when planning future lifts.

These guidelines do not intend to prescribe any system, but simply offer guidance on elements of a robust system incorporating minimum standards. Users are encouraged to improve on these standards in reducing risks when carrying out lifting and m e c h a n ic a l h a n d l in g o p e r a tio n s .

12

L IF T I N G & M E C H A N I C A L H A N D L IN G G U I D E L I N E S

7 appendices Lift Plan Part 1

p 14

Lift Plan Part 2

p 15

Too lbo x Talk C hec klist

p 16

Prompt Card – Example

p 17

Risk M atrix – Exam ple

p 18

Key Terms an d Definitions

p 19


13

LIFT P LAN

Part 1 (To be completed by the Competent Person)

Ins ta lla tio n/S hip/B a rg e /Othe r: P ermit to Work No:

Lo c a tio n (ma in d e c k, b a c k d ec k, q ua ys id e e tc ): Risk Asse ssme nt No:

Lift Plan Number:

Weight of Loa d, Actual or Asse sse d (delete as applicable) :

DESCRIPTION OF LIFTING OPERATION

POSSIBLE CONSIDERATIONS (not exhaustive) (Tic k if relevant and add ress each point in ‘Step-by-Step ’ section below )

Weig ht not ve rified

Lifting of chemicals

Conflicting ta sks in area

High c entre of gra vity

Load on pa llet req uires sec uring

Dynamic fa ctors involved

Sta bility of loa d

Sea fastening removed

Haza rds to personnel in the area

Awkwa rd s ize/sha pe/sha rp ed ges

Restricted headroom or confined work area

Communication req uirements

No dedica ted lifting po ints on the load

No lifting point directly above the load

Ade q uat e light ing and visibility

No certified suspens ion points for the lifting eq uipment

Appropriate and correctly installed lifting equipment and accessories

Is the use of ta g lines req uired? Then co nside r personne l pos itioning

ROUTE TO BE TRAVELLED AND LAYDOWN AREA (If y ou c a n’ t a n sw e r eit h er, a d d re ss in t h e ‘ St ep - b y- S te p ’ s ec t io n )

YES

N/A

1) Are the route and laydow n area clear of obstructions? 2) Is the laydown/landing area a deq uate in terms of size and load-bea ring a bility? 3)

Is suitab le pac king ava ilab le for protection of the loa d, lifting eq uipment, slings etc ?

4) Have barriers been positioned to prevent acc ess by unauthorised personnel? 5)

Have you confirmed tha t the layd own a rea is within the operating limits/radius of the eq uipment?

6) Have environmental conditions been considered w ith regards to the s afety of the lifting operation? 7)

Will the Lifting Equipment Operator be able to see the Ba nksman throughout the operation, or has a nother suitab le, risk-ass essed means of communication been c hecked and made available (eg radios)?

8) Are there haza rdous process plant or materials in the area?

STEP-BY-STEP DETAILS OF THE LIFTING OPERATION

14


(Person Responsible)

t e n . y t e f a s n i e g n a h c p e t s . w w w : e t i s b e W y t e f a S n i e g n a h C p e t S e h t n o e l b a l i a v a s i m r o f s i h T • s e n i l e d i u G g n i l d n a H l a c i n a h c e M d n a g n i t f i L • y t e f a S n i e g n a h C p e t S

LIFT P LAN

Part 2 (To be completed by the Competent Person)

SKETCH DETAILING THE RIGGING UP OF THE LIFTING EQUIPMENT AND LIFTING ACCESSORIES

LIFTING EQUIPMENT AND LIFTING ACCESSORIES TO BE USED (Specify type and SWL)

DEBRIEF AND LEARNING POINTS (Did the lifting operation go as planned or are changes to the lift plan required?)

Competent Person

Print Name:

Signature:

Date:



15

T O O L B O X TA LK C H E C K L I S T All perso nnel involved in the w ork ac tivity mus t pa rticipa te in the Toolbo x Ta lk (TBT) an d s ign be low a s b eing p resent . The TBT objective is to communicate the Activity Tas k Asse ssm ent a nd c apture a ny sp ecific controls not a lrea dy identified to the work pa rty. Work Loca tion:

Work Act ivity:

Da te :

Dis c ipline:

P erm it, W/O or Proced ure No:

TRA, Lift P lan, C OS HH, or Manua l Handling No:

CHECKLIST/PROMPT (Tick where appropriate)

Type o f operation to b e exec uted

Work eq uipment

Hazardous substances used/present

Methods/procedures to be a dopted

P roduction/operational cons traints

Isolation req uireme nts

P TW p reca utions/co ntrols

Human factor asse ssment

Conflicting activities

Safety equipment location

Cra ne/lifting req uireme nts

Environmental cons iderations

Individua l res pons ibilities for co ntrols

Confined space entry requirements

Waste manag ement

Acce ss /egress

Manual ha ndling

Working environmenta l cond itions

Tes ts /mo nito ring

Potential hazards

OPERATIONS SUMMARY

EQUIPMENT SUMMARY

SAFETY TOPICS DISCUSSED

ATTENDEES P rint Na me

S ig na ture

P rint Na me

S ig na ture

TALK CONDUCTED BY

16

Procedures

Planned By

Print Name:

Signature:

Date:

Ta lk Ca rried Out By

Print Name:

Signature:

Date:

L IF TI N G & M E C H A N I C AL H A N D L I N G G U I D E LI N E S

Risk Assessment Other Documents


P R O M P T C A R D – E X AM P L E

Part 1

P l a n n i n g t h e L if t

(Competent Person)

• Is there a new or existing lift plan which is adequate for the lifting operation? • Has a risk assessment been undertaken and the risks managed through the control measures within the lift plan? • Is the equipment selected fit for purpose and identified in the lift plan? • Do the personnel selected to undertake this lifting operation have the correct level of competence? • Have the steps of the lift plan been communicated and understood by all involved?

Part 2

J o b S it e R e v i e w

(Everyone involved in the lift)

• Is there a lift plan and risk assessment for the lifting operation and do they fully cover the actual task to be undertaken? • If this is a generic lift plan for a routine lifting operation, are there any changes for this lif ting operation compared to the generic plan, eg c hange in weight, change in centre of gravity, wind, lighting? • Have you the authority/PTW required to proceed with the lift?

• What could go wrong? ...has this information been fed into the lift plan and Task Risk Assessment?

• Have you assessed the path the load will take?

• Have all potentially affected parties been informed of the lifting activities?

• Have all seafastenings/hold-downs been released?

• Have you prepared the load setdown area? • Have you assessed tagline/hold-back requirements? • Has the lifting equipment been checked? Is it fit/appropriate for use? • Is adequate supervision present and who will be in control of the lifti ng operation? • On vessels, have you considered stability, dynamics and vessel motion? • Have all personnel involved been fully briefed? • Are communications adequate? • Has the site been checked for potential dropped objects? • Have the environmental conditions been considered, ie wind, rain etc? • Are the steps of the lift plan and individual responsibilities clearly understood by all those affected and/or involved? • Are personnel in the vicinity aware of the lift?

t e n . y t e f a s n i e g n a h c p e t s . w w w : e t i s b e W y t e f a S n i e g n a h C p e t S e h t n o e l b a l i a v a s i d r a c s i h T • s e n i l e d i u G g n i l d n a H l a c i n a h c e M d n a g n i t f i L • y t e f a S n i e g n a h C p e t S

Additional useful guidance:

UKOOA

‘Guidelines for the Safe Packing and Handling of Cargo to and from Offshore Locations’

Step Change in Safety

Step C hange in Safety

‘best practice guide to handling tubulars’

‘best practice guide t o m a n r i d i n g s a f e t y’

www.dropsworkpack.com

‘Guidance on eliminating the i n c id e n c e o f d r o p p e d o b j e c t s f r o m w i t h i n d r i ll i n g d e c k structures’

L IF TI N G & M E C H A N I C AL H A N D L I N G G U I D E LI N E S

17

R I S K M AT R I X – E X A M P L E T h e f o l lo w i n g i s a n e x a m p l e o f a t y p i c a l R is k M a t r ix . R e f e r t o t h e S t e p C h a n g e i n S a f e t y T R A G u id e f o r f u rt h e r in f o r m a t io n . H a z a r d S e v e r it y

e V e r y U n l i k e l y c A freak combination of would be required n factors for an incident to result e r U n l i k e l y r A rare combination of factors u would be required for an c incident to result c Possible O Could happen when f additional factors are present o but otherwise unlikely to occur d L i k e l y o Not certain to happen but o an additional factor may result in an accident h i l e k i L

N e g l ig ib le

S lig h t

M oderate

H ig h

V e r y H ig h

Negligible injury, no absence from work

Minor injury requiring first aid treatment

Injury leading to a lost time accident

Involving a single death or serious injury

Multiple deaths

LO W

LO W

LO W

LO W

LO W

LO W

LO W

LO W

M E D IU M

M ED IU M

LO W

LO W

M E D IU M

M E D IU M

HIGH

LO W

M E D IU M

M E D IU M

H IG H

H IG H

M E D IU M

M E D IU M

H IG H

H IG H

H IG H

Very Likely Almost inevitable that an incident would result

LOW RISK

M a y b e a c c e p t a b l e b u t r e v ie w t a s k t o s e e i f ris k c a n b e r e d u c e d f u rt h e r.

M E D IU M R IS K

Ta s k s h o u ld o n l y p r o c e e d w i t h a p p r o p r ia t e m a n a g e m e n t a u t h o r is a t io n a f t e r c o n s u l t a tio n w it h s p e c ia lis t p e r s o n n e l a n d a s s e s s m e n t t e a m . W h e r e p o s s ib l e , t h e t a s k s h o u l d b e r e d e f in e d t o t a k e a c c o u n t o f t h e h a z a r d s in v o l v e d o r t h e r is k s h o u l d b e r e d u c e d f u r t h e r p r io r t o ta s k c o m m e n c e m e n t .

HIGH RISK

Ta s k m u s t n o t p r o c e e d . It s h o u l d b e r e d e f in e d o r f u rt h e r c o n t r o l m e a s u r e s p u t in p l a c e t o r e d u c e r is k . T h e c o n t ro l s s h o u l d b e r e a s s e s s e d f o r a d e q u a c y p r io r t o t as k c o m m e n c e m e n t.

By redefining the hazard severity, risk evaluation matrices can be used to assess health, production and e n v i ro n m e n t a l ris k a s w e l l a s t h e r is k o f a c c id e n t a n d in j u ry . A n e x a m p l e o f t h e s e d e f i n it io n s m a y b e : Negligible N e g l i g i b l e i n j u r y o r h e a l t h i m p l i c a t i o n s , n o a b s e n c e f r o m w o r k . N e g l i g i b l e l o s s o f function/production with no damage to equipment or the environment.

18

Slight

M in o r i n ju r y r e q u i rin g f ir s t a id t r e a tm e n t o r h e a d a c h e , n a u s e a , d iz z in e s s , m ild r a s h e s . D a m a g e t o e q u ip m e n t r e q u i rin g m in o r r e m e d ia l re p a i r, lo s s o f p r o d u c t i o n o r i m p a c t o n t h e e n v ir o n m e n t .

Moderate

E v e n t le a d i n g t o a l o s t t im e in c i d e n t o r p e r s is t e n t d e r m a t i tis , a c n e o r a s t h m a . L o c a lis e d d a m a g e t o e q u i p m e n t r e q u i rin g e x t e n s iv e r e p a i r, s i g n if ic a n t l o s s o f f u n c t i o n / p r o d u c t i o n o r m o d e r a t e p o llu t io n in c u r rin g s o m e r e s t i tu t io n c o s t s .

High

Involving a single death or severe injury, poisoning, sensitisation or dangerous infection. D a m a g e t o e q u ip m e n t r e s u lt in g i n p r o d u c t io n s h u t d o w n a n d s i g n i fic a n t p r o d u c t i o n lo s s . Severe pollution with short-term localised implications incurring significant res titution costs.

Very High

Multiple deaths, lung diseases, permanent debility or fatality. Major pollution w ith long-term implication and very high restitution costs.

L IF T I N G & M E C H A N I C A L H A N D L IN G G U I D E L I N E S

K E Y TE R M S A N D D E F IN I T IO N S Assessment

Process of judging com petency against prescribed standards.

Assessor

P e rs o n w h o m a k e s a j u d g e m e n t o f competency against prescribed standards.

Banksman

A Co mp etent Person po sitioned s o that he has an unrestricted view of the load and the Crane Operator, to give load manoeuvring instructions to the Crane Operator via hand signals or radio.

Check

A visual and func tional asse ssm ent o f lifting equipment and lifting accessories (not a test) prior to use.

Lift Plan

A written document which will include details of how the lifting operation should be und ertaken, the lif ting equ ipm ent and lifting a c c e s s o r ie s t o b e u s e d , h o w t h e e q u ip m e n t and acc essories should be rigged up and the control measures in place to m anage the risks iden tified in the Task Risk Asses sm ent.

LOLER

Lifting O pe rations and Lifting Eq uipm ent Regulations.

PUWER

Provision and Use o f Work Equipment Regulations.

Signaller

Person resp ons ible for relaying a c rane m oveme nt signal to the C rane Op erator. Note: See also Banksman.

Normally termed

Colour Code A me thod of m arkin g eq uipm ent to give a visual indication of its certification status.

the Banksman

Sling Cogent (OPITO)

Sec tor Skills Cou nc il for the O il and Gas Extraction indu stry.

Factor o f Safety

The ratio of the load that would cause the failure of an item of lifting eq uipm ent to the m aximu m load that can be imp osed u pon it in service ie SW L. (This is to allow for de trim ental criteria suc h as w ear and tear, dynam ic loadings etc.)

Fit-forpurpose

Equipment free from defect and used only in the manne r for which it was d esigned.

Inspection

A visual check and, if necessary, a function chec k of the liftin g e quipmen t by a Co m petent Person at intervals b etween the ‘thorough e xam inations’. In d etermining the suitability and scope of the inspection, reference sho uld b e m ade to information such as m anufacturers’ instructions and relevant standards.

Lifting Equipment

Wo rk equipmen t (machinery, app liance, app aratus or to ol) for lif ting or lowe ring loads, including the attachm ents used for anc horing, fixing o r supp orting it. For exam ple, cranes , forklift truc ks, c hain hoists, lever hoists and winches.

Lifting Gear/ Equipment used for attaching the load to the Accessories lif ting m ach inery, eg slings , sh ackles, eyebolts etc. Lifting Operation

An operation concerned with the lifting or lowering of a load .

W ire ropes , chains, synthetic w eb and me tal m esh m ade into forms, w ith or without fittings , for h and ling loads .

Slinger/ The person responsible for the attaching, Load Handler detaching and secu rin g o f the loads to the lif ting e qu ipm ent. Also resp ons ible for the selection and the us e o f lifting gear/acc essories in ac cordanc e w ith the lift plan. The S linge r or Load Hand ler signals to the B anksm an that the lifting gear/acc essories are correctly attached and the load is ready for lifting. Task Risk Assessment

A system for the ide ntification of the hazards associated with the task, assessing the risks and identifying the controls/precautions required to m itigate tho se risks.

Thorough Examination

An examination c arried o ut by a Co mp etent Person to arrive at a reliable co nc lusion as to the co ndition and safety of the equipm ent. The C om petent Person w ill determine the extent of the thorough examination – this may involve dism antlin g an d tes ting.

Toolbox Meeting Toolbox Talk (TBT)

A discussion held b etween all me mb ers of a lifting o peration p rior to c om m encem ent of work in order to agree on all aspects of the wo rk and the sequential steps to b e taken to complete the work.

Training

A p r o g ra m m e d r a w n u p t o t e a c h a p e r s o n the nec essary skills and kno wledg e to fulfil a function/job.


19

t h e l i f t in g a n d m e c h a n ic a l h a n d lin g w o r k g r o u p A c k n o w le d g e m e n t s S t e p C h a n g e in S a f e ty w o u l d l ik e t o t h a n k s e v e r a l in d i v id u a l s f ro m a w id e r a n g e o f c o m p a n i e s a n d o r g a n is a t io n s w h o g a v e r e s o u r c e s a n d t im e t o d e v e l o p t h e s e g u i d e l in e s . P a r tic u l a r a c k n o w l e d g e m e n t f o r v a lu a b l e c o n t rib u t i o n is g i v e n t o t h e m e m b e r s o f t h e c o r e te a m w h o s e c o m p a n i e s and organisations are listed below.

20

AMEC

Sigma 3

G rampia n Tes t &C ertifica tion

S pa rrow s Offshore Service s Ltd

Halliburton

S tep Cha nge in Sa fety (ESR Network)

HSE (UK Health and S a fety Executive)

Subsea 7

IADC (North Sea Chapter)

Trans oc ea n

IMCA

UKOOA

Schlumberger

Woo d G roup Enginee ring (North S ea ) Ltd


For further information on Lifting and M echanical Handling go od practices and electronic versions of these Guidelines please visit the Step Chang e in Safety web site: www.stepchangeinsafety.net

Step Change Support Team PO Box 10406 Aberdeen AB12 3YL 01224 881272

01224 882350

info@stepc hangeinsafet y.net

For all the mo st recent inform ation and resources please visit:

www.stepchangeinsafety.net

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