1.0 Purpose

This procedure is prepared to ensure effective management on Lifting Operation and Lifting Accessories to minimize risk due to the material handling operation.

2.0 Scope

The procedure is applicable to HSC Facilities to fulfill the general and also the legislative requirement.

3.0 Responsibilities

3.1 Unit Head

Ensures that the procedure is followed during Lifting Operation

3.2 HSE Representative

Ensures that only trained personnel are engaged.

Conducts awareness program for the personnel engaged on such jobs

Monitor and audit implementation of this procedure

3.3 Operational Managers / Maintenance Managers

Responsible for proper deployment of trained personnel.

Ensure proper lifting accessories are present.

3.4 Competent Person

Responsible for periodic checking of lifting tools and accessories as per legal requirement.

3.5 Employees

Employees’ engaged in lifting operations must:

Never put any part of their body under a suspended load

Never ride a load while it is being lifted

Be aware of suspended loads, signals of the operators and any lifting equipment supports

Use lifting equipment as instructed and report any defects

4.0 Description

4.1 Definitions

Appointed Person: A person with the training, practical and theoretical knowledge and experience required for the planning, organization and control of lifting operations Slinger and Signaler: Person who fastens the slings with the job and directs the operation of a crane from the point near where loads are attached and detached Competent Person: Person trained, experienced and authorized to carry out a particular function

Lifting Accessories: Equipment used to attach loads to machinery for lifting. Includes single items (such as a shackle) or an assembly of items (such as lifting beam and slings), which may be used to secure the load to the piece of lifting equipment. Other examples include: slings, swivel or eye bolts, hooks, clamps

Lifting Equipment: Equipment for lifting and lowering loads e.g. cranes, passenger and goods lifts, forklifts, scissor lifts, reach stackers. Also, includes attachments used to anchor, fix or support the equipment (e.g. the runway of an overhead crane)

Rigging: Installation of the slings (or other lifting accessories) and fixing the load to the crane

SWL Safe Working Load: Sometimes referred to as “Rated Load”

Planning: Major rigging operations must be planned and supervised by competent personnel to ensure that the best methods and most suitable equipment and tackle are employed.

Supply and Care of Rigging: Management must ensure that:

Proper rigging equipment is available

Correct load ratings are available for the material and equipment used for rigging

Rigging material and equipment are maintained in proper working condition Rigging Operation: The Supervisor of the rigging operation is responsible for:

Proper rigging of the load

Supervision of the rigging crew

Ensuring correct assembly of rigging material or equipment as required during the operation, such as the correct installation of lifting bolts

Safety of the rigging crew and other personnel as they are affected by the rigging operation

4.2 Process

4.2.1 Control of Lifting Equipment

Golden Rules LIFTING OPERATIONS

Lifts utilizing cranes, hoists, or other mechanical lifting devices will not commence unless:

an assessment of the lift has been completed and the lift method and equipment has been determined by a competent person;

operators of powered, lifting devices are trained and certified for that equipment;

rigging of the load is carried out by a competent person;

lifting devices and equipment has been certified for use within the last six (6)

months (at a minimum);

load does not exceed dynamic and/or static capacities of the lifting equipment;

any safety devices installed on lifting equipment are operational;

all lifting devices and equipment have been visually examined before each lift by

a competent person.

Ensure no one standing or working below suspended load.

4.2.2 Identification and SWL

All lifting equipment must be clearly marked with a unique identifier and the safe working load (SWL), where this is not possible, a coding system should be used which allows the user to determine the SWL e.g. color coding or attaching some form of label.

Where the safe working load depends upon the equipment’s configuration, this must be clearly identified for each configuration. Alternatively, this information must be retained with the equipment.

Lifting beams must be clearly marked with their weight and SWL and must only be used for the purpose for which they were designed.

The maximum SWL of most lifting equipment is determined from static loads and a safety factor applied to account for dynamic motions of the load and equipment. In order to ensure that the SWL is not exceeded during operation, allowances must be made for wind loading and dynamic forces set up by the normal operational movements of the machine and load.

4.2.3 Lifting Equipment Registration

Each Site must keep a register of all items of lifting equipment, containing the following:

Identification details

Date when equipment was purchased

Copy of the Test Certificate (only equipment with current test certificates may be used)

Date when equipment was first taken into use

Date of each examination, who carried it out and the certificate number

Date of re-test

Particulars of each defect found and the steps taken to remedy such defects

Dates of any heat treatment or normalizing of chains or slings

4.2.4 Custom-made Lifting Devices

Any custom-made lifting device must be:

Designed by a qualified person

Designed with a safety factor of 5

Proof tested to 125% of rated capacity iv. Marked with the rated capacity

Certified by a competent body

Inspected every 6 months

4.2.5 Defective and Lost Lifting Equipment

Items of lifting equipment identified as not complying with legislative requirements, or by users having doubts on its safety, must be quarantined and clearly labeled as defective to prevent accidental usage These items must then be either:

Repaired and, once repaired, re-certified by a Competent Person before being placed back into service, or

Items that are lost are to be recorded as such in the lifting equipment register

4.2.6 Handling and Storage

Wire ropes must never be allowed to lie on the ground for any length of time or on damp or wet surface, rusty steel or near corrosive substances. They must be stored in a clean dry place; wire rope slings must be cleaned after use, inspected and hung on pegs to prevent corrosion and kinking

Lifting accessories must be stored in conditions that do not lead to damage or deterioration.

Slings must be hung up to prevent damage

Chain blocks, turn buckles, chains and similar tackle should be hung up and lightly oiled

All rope must be kept away from flame cutting and electric welding operations

Avoid contact between any sling and solvents and chemicals. vii. Suitable precautions should be taken to prevent any sharp edges of loads coming into contact with slings

4.2.7 Thorough Examinations and Inspections

Any new equipment that has not been used before are accompanied by a test certificate/declaration of conformity, which confirms that the equipment has undergone a thorough examination (not more than 12 months previously) and specifying the SWL, prior to first use.

A thorough examination is to be performed following the repair or replacement of a structural component

All other lifting Equipment must undergo a thorough examination at least every 12 months

For passenger lift in Administrative Building, it is ensured that the passenger lift is safe to use and that it receives periodic thorough examinations and inspections, in accordance with local regulations.

Lifting accessories / attachments must be visually inspected on each occasion before use.

4.2.8 Planning and Control of Lifting Operations

Categorization of Lifting Operations Lifting operations are categorized as under:

Routine – repetitive lifting operations, examples of lifting equipment generally provided for routine lifting operations include:

Regular shop floor material movement

Fork-lift trucks in a warehouse

Construction site hoist

Mobile elevated work platform (MEWP) used for general maintenance

A vehicle tail lift

Non-Routine – lifting operations which meet on or more of the following criteria:

Operation involving more than one item of lifting equipment

The load being lifted exceeds 5000kg

Load either exceeds 50% of the crane SWL or is =>75% rigging SWL

A critical component is being lifted

Operation with load tilting

Lifting people or where there is a potential hazard for people

Lifting near to existing buildings or hazardous installations (flammable liquids storages, high-voltage line etc.)

Non-routine operation carried out with mobile lifting equipment

Operation carried out with temporary lifting equipment

Use of equipment not specifically designed for lifting (backhoe excavator)

Lift of load without any defined hooking points

Operation were operator cannot see the load

Operation needing assistants to guide the load during the load setting

Risk Assessment and Lifting Plans

Risk Assessments

A risk assessment must be prepared for all lifting operations. ii. For routine lifting operations an initial risk assessment and lifting plan is required but need not be repeated i.e. generic risk assessments and lifting plans may be used. However, they must be subject to regular documented reviews (at least annually) to ensure that they are still valid. iii. For all non-routine lifting operations a task specific risk assessment and lifting plan / method statement must be prepared for every operation

Lifting Plans

Every lifting operation is planned and controlled by the concerned supervisor who ensures that safe procedures are undertaken. Factors to be considered when planning lifting operation include the following:

Identification of lifting operations to be performed and load characteristics − Determine the load characteristics e.g. weight, center of gravity, stability, and physical size. Making ample allowances for unknown factors, and determine the available capacity of the equipment being used. In cases where the assessment of load weight is difficult, safe load indicators of weighing devices must be fitted. It is equally important to rig the load so that it is stable. Unless the center of gravity of the load is below the hook, the load will shift.

While planning for lifting a load the path of the lift must be considered

Lifting equipment must be positioned to ensure that it is installed to reduce as low as is reasonably practicable the risk of the equipment or load striking a person or from the load drifting or falling freely, or being released unintentionally, and that it is otherwise safe

Determine the means of communication e.g. line of sight signaler to crane driver or whistles. Unless voice communication equipment (telephone, radio or equivalent) is utilized, signals must be discernible or audible at all times. No response must be made unless signals are clearly understood

Ensure that the signaler is readily identifiable by and visible to the crane operator

Identification and positioning of equipment to be used

Determine lifting equipment position i.e. where it is to be sited to make the lift

Determine suitability of ground to ensure equipment stability i.e. is the ground sufficiently competent to support the predicted ground loading imposed by the lifting equipment and the load

Determine access and egress route and any restrictions i.e. the route to the site if necessary as well as the route from the site entrance gate to the identified lifting equipment operating position

4.2.9 General Safety

Personnel Safety

The safety of personnel involved in lifting operations largely depends upon care and common sense. The following practices must be followed:

Never

Exceed the SWL of the equipment being used

Allow any person to be part of the load by riding on equipment being lifted

Allow a load to be carried over the heads of any personnel iv. Work under a suspended load unless the load has been adequately supported from the floor and the supervisor in charge of the operation has approved all conditions

Leave a load suspended in the air when the hoist or crane is unattended

Put any part of the body under a suspended load

Always

Examine all hardware, equipment, tackle and slings before using it and destroy defective components

Determine the load weight before rigging it

Make sure that all personnel stand clear while loads are being lifted and lowered or while the slings are being drawn from beneath the load. The hooks may catch under the load and suddenly fly free

Be aware of suspended loads, signals of the operators and any lifting equipment supports

Lifting Equipment Operators

Operators must not engage in any practice, which shall divert their attention during lifting operations

Operators must respond to signals from the signaler. When a signaler or a crane follower is not required as part of the crane operation, the operator is then responsible for the lifts. However, the operator shall obey a stop signal at all times, no matter who gives it.

The operator must be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator must promptly report this to the Appointed Person, and must also notify the next operator. iv. The operator prior to a new lift must test all controls. If any controls fail to operate properly, they will be adjusted or repaired before operations are begun.

Where applicable, the manufacturer's balancing bar and lifting procedures must be followed. Any deviation from the manufacturer's procedure must be promptly reported to the Appointed Person

4.2.10 Hire of Lifting Equipment and Services

All mobile cranes and lifting equipment brought onto Site must have valid test certificates to demonstrate they have been inspected before being allowed to operate on site.

If lifting equipment of services are to be hired / purchased, responsibilities for supply of equipment, personnel and documentation must be agreed in the contract.

5.0 Records

Records of testing of Lifting Tools and Accessories

Training Records.