QP Standard for Lifting Equipment and Operations PDF
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Uploaded by DecentBoston
2020
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Summary
This document outlines the minimum safety requirements for lifting equipment operations within QP's operational areas, including certification requirements, maintenance procedures, and testing. It covers various aspects of lifting equipment, including inspection, colour coding, and lifting tackle.
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A N ts 01/11/2020 Jsj ,,U r-LA Qatar Pehokum FoR LI Frr NG E3[,BilIT,?11? opERAnoNs DOC NO: QP-PA|-STD-005 Description.' lssued for Use Rev:00 CUSTODIAN QUALITY REVIEWED BY DOCUMENT OWNER DEPARTMENT Ahmed Abdulrahman Digitally signed by CORPORATE HSE & ,€+>.q_Q q> _ Albakri Alyafei 2o2o.oe. 1 o o7:03:3e Stephen Combey Date:2020.09.15 QUALTTY (BC) +03'00' 07:0'l:41 +03'00' BCQ BC FINAL APPROVAL Digitally signed by NABEEL MOHAMMED ALI AL. BUENAIN Date: 2020. 1 0.06 1 4:00:27 +03'00' VB l'*,{*{//"il; PRESIDENT & CEO SECURITY CLASSIFICATION: INTERNAL QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 TABLE OF CONTENTS Page No. PURPOSE......................................................................................3 SCOPE AND APPLICABILITY......................................................3 STANDARD...................................................................................4 3.1 CERTIFICATION REQUIREMENTS FOR LE INSPECTION AND LE PERSONNEL................................................................................................ 4 3.2 COLOUR CODING....................................................................................... 4 3.3 LIFTING APPLIANCES................................................................................. 4 3.4 LIFTING TACKLE (LOOSE GEAR).............................................................. 5 3.5 TESTING EQUIPMENT................................................................................ 5 3.6 MAINTENANCE REQUIREMENTS.............................................................. 5 3.7 NONDESTRUCTIVE TESTING (NDT) REQUIREMENTS............................ 5 3.8 SINGLE LIFTING POINT POLICY................................................................ 5 3.9 HSE AND QUALITY REQUIREMENTS........................................................ 6 3.10 CRITERIA AND CATOGERIES OF LIFTING OPERATIONS....................... 6 3.11 CONTROL MEASURES OF LIFTING OPERATIONS.................................. 7 3.12 RESTRICTIONS FOR LIFTING OPERATIONS........................................... 8 3.13 INCIDENT REPORTING AND INVESTIGATION......................................... 9 VALIDITY PLAN............................................................................9 REFERENCES TO OTHER DOCUMENTS....................................9 DEFINITIONS............................................................................... 14 APPENDIX........................................................................................... 17 APPENDIX A - COMPETENCE REQUIREMENTS FOR QP/CONTRACTOR LE PERSONNEL............................................................................... 17 Appendix B - REQUIREMENTS FOR LIFTING APPLIANCES............................. 20 APPENDIX C - REQUIREMENTS FOR LIFTING TACKLE (LOOSE GEARS)..... 38 APPENDIX D - WIRE ROPE ON LIFTING APPLIANCE DISCARD CRITERIA... 47 APPENDIX E - USE OF LE DURING NON-ROUTINE COMPLEX LIFT FORM (QP-PAI-STD-005-E)................................................................... 48 APPENDIX F - REQUEST FOR WAIVER FORM (QP-PAI-STD-005-F).............. 49 APPENDIX G - USE OF LE DURING NON-ROUTINE SIMPLE LIFT FORM (QP- PAI-STD-005-G)........................................................................... 50 APPENDIX H - REVISION HISTORY LOG.......................................................... 51 SECURITY CLASSIFICATION: INTERNAL Page 2 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 PURPOSE The purpose and intent of this standard is to: Outline the minimum requirements for the safe use and operation of Lifting Equipment (LE) and Fall Protection Equipment (FPE) in accordance with statutory requirements, QP’s Corporate Philosophy for Fire and Safety (QP- PHL-S-001) and Corporate Integrated Management System Manual (QP-IMS- MAN-01). Ensure systematic planning and implementation of safe lifting operations within QP’s operational areas by establishing, and maintaining safe working practices for QP personnel surrounding environment and assets. SCOPE AND APPLICABILITY The scope of this standard shall apply for the following: Safe utilisation of all LE utilised in all QP operational areas, its contractors and sub-contractors. The maintenance, inspection, testing, lifting operations and organisational setup for safe use of LE. All QP and contractor owned and operated LE utilised to raise, lower, suspend a load. All personnel involved/engaged in any lifting operation and their experience, qualification, competency and training requirements. Buyers, vendors, users, contractors and sub-contractors, and all QP’s departments, with clear identification of their responsibilities to prevent the use of any obsolete and/or uncertified LE and LE personnel. All LE and LE personnel on vessels/barges, contracted, owned and/or operated by QP, which is not covered under the classification or competent authority recognised by the flag state, shall be inspected and certified to conform to this standard. All routine and non-routine lifting operations shall have risk assessment and standard operating procedures (SOP) accepted by QP competent person (LE) to conform to this standard. Note : Vessels calling at QP operated ports for cargo operations using ship’s cranes are complying with their classification/flag state requirements and hereby exempted from the requirements of this standard. However, QP’s competent person (LE) will make evaluation of areas of suitability of application and insure valid certificates are available. SECURITY CLASSIFICATION: INTERNAL Page 3 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 STANDARD 3.1 CERTIFICATION REQUIREMENTS FOR LE INSPECTION AND LE PERSONNEL Any reference in this standard to the inspection, testing, training and certification of any LE or LE personnel, shall mean that such documents are issued by a QP Approved Inspection Service Provider and/or QP Approved Training Service Provider. Certificates Issued For LE Inspection No lifting equipment shall be used unless a QP approved Inspection Service Provider has issued a certificate, which has been accepted and endorsed by QP Competent Person. All lifting equipment certificates submitted for endorsement shall be supported with previous QP endorsed certificate or manufacturer's certificate of conformity (COC), complying with this standard. All original LE certificates shall be issued as shown in sample formats in QP Corporate Procedure for Lifting Equipment Doc. No. QP-PAI-PRC-004 and shall be in accordance to the latest Lifting Operations and Lifting Equipment Regulations (LOLER) Schedule 1. Certificates Issued For LE Personnel Training All original LE Personnel Training certificates shall be issued as shown in sample formats in QP Corporate Procedure for Lifting Equipment Doc. No. QP- PAI-PRC-004. Identification cards shall be issued showing the name of the person, photograph, type of training, certificate number and validity of the certificate. 3.2 COLOUR CODING QP operates a system where all LE is marked with a designated colour according to the scheduled inspection period and year. The validity of the colour is six (6) months. Any equipment inspected on a facility outside the scheduled inspection period shall be marked with the same colour as the rest of the facility to avoid any double colour coding possibilities. The colour code shall be confirmed, as published by QP’s Corporate HSE&Q Department and prominently displayed on boards at each facility. Equipment not marked in accordance with the required colour code shall not be utilised in any QP operational areas or facilities. Red colour shall be reserved for items that are not fit to be used. Items that are scrap shall be marked red and in addition tagged as “scrap”. Contractors operating within QP operational areas shall comply with QP colour code system for contractors as published by QP’s Corporate HSE&Q Department. 3.3 LIFTING APPLIANCES Appendix B shall be complied for the requirements of lifting appliances. SECURITY CLASSIFICATION: INTERNAL Page 4 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 3.4 LIFTING TACKLE (LOOSE GEAR) Appendix C shall be complied for the requirements of lifting tackle. 3.5 TESTING EQUIPMENT Load Cells Load cell calibration and verification shall be as per the following, as minimum requirement: The load cell shall be calibrated and certified annually by an accredited laboratory. In the absence of accredited laboratories, calibration shall be performed annually by a recognised test facility and witnessed and certified by a QP Approved Inspection Service Provider. Load Testing Machine Calibration And Verification The load testing machine shall be calibrated and certified annually by an accredited test body. In the absence of accredited laboratories, calibration shall be performed annually by a recognised test facility, witnessed and certified by a QP Approved Inspection Service Provider. 3.6 MAINTENANCE REQUIREMENTS All lifting equipment shall be properly maintained in accordance with the manufacturer's recommendations. The Asset Owner shall allocate storage areas for storage of LE, quarantine area for scrap items and develop and implement a routine maintenance program that will ensure proper maintenance of the LE as per the manufacturer's recommendation. QP Approved Inspection Service Provider shall check all maintenance, service, and wire rope inspection records of LE during the thorough examination. Computer based or soft copy maintenance records shall be accepted. 3.7 NONDESTRUCTIVE TESTING (NDT) REQUIREMENTS NDT shall be performed on all LE such as cranes, forklifts, containers, skips, baskets, cradles, cylinder rack, pallets etc., as required by the original equipment manufacturer (OEM), the relevant standards, QP relevant corporate standard for NDT, Doc. No. QP- STD-R-008 and the discretion of the QP Approved Inspection Service Provider. 3.8 SINGLE LIFTING POINT POLICY QP recommends the use of multiple lifting points for all lifting activities. QP shall only accept the lifting of loads that have been designed with a single lifting point, with confirmation from OEM. The design load for such pad eye shall be five (5) times gross weight, tested to two (2) times gross weight, certified by a QP approved inspection service provider and accepted by a QP competent person (LE). SECURITY CLASSIFICATION: INTERNAL Page 5 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 3.9 HSE AND QUALITY REQUIREMENTS Contractor’s HSE And Quality Requirements All contractors working for QP shall comply with: Corporate Standard for Quality Requirements for Projects, Doc. No. QP- STD- Q- 004. QP HSE Regulation for Contractors, Doc. No. QP-REG-S-001. QP’s HSE And Quality Requirements Audits on QP Departments shall be conducted in accordance to corporate HSE&Q requirements. Corporate Management System Manual (QP-IMS-MAN-01). 3.10 CRITERIA AND CATOGERIES OF LIFTING OPERATIONS Routine Simple Lifting Operations Uncomplicated lifts that are performed on a regular basis, which involve basic slinging practices with maximum load up to five tonne, such as handling of pipe, tubulars, containers, the loading/unloading of trucks, usually performed by the deck crew, warehouse or yard personnel. No lifting plan is required unless it is deemed necessary by QP competent person at site. Non- Routine Simple Lifting Operations Lifts that involve the use of basic hoisting equipment with load above 5 tonne and up to 50 tonne, provided none of the non-routine complex lifts criteria is applicable. For example; a crane or manual hoist (suspended from dedicated lifting structures such as pad eyes or runway beams) directly above the load. Loads shall have certified lifting points. (Refer to Appendix E - FORM3) Non- Routine Complex Lifting Operations These lifts could be any of the first two categories but with additional hazards, as detailed below: Lifts that exceed 50 tonnes in weight. Any load dimension exceeds 15 meters or the load is of a complex shape where the centre of gravity (COG) is difficult to ascertain. Lifts which exceed 30 meters in height. Lifts which require full boom extension. Lifts requiring use of more than one crane simultaneously (Tandem lift). For more details refer to QP Guideline for Simultaneous Operation (SIMOPS). Lifts where the equipment/load consists of thin/fragile members susceptible to deformation during lifting. Lifts operated within and over live plant or assets that contain hazardous inventory that are encapsulated within the Crane Footprint. Lifting in-service pipeline, lifts over live pipelines, near overhead electric power lines where lifting operation can endanger the safety of the facility, crane or personnel. SECURITY CLASSIFICATION: INTERNAL Page 6 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Personnel lifts / lifts where safety of personnel and equipment are at risk. All lifts where the crane operator does not have direct line of sight of the load. All lifts through hatches, confined spaces and congested areas. Any lifting operations planned to be performed after sunset or during periods of poor visibility. 3.11 CONTROL MEASURES OF LIFTING OPERATIONS General All lifting operations categories shall be planned (except routine simple lifting operation), risk assessed, documented and performed by competent persons using the appropriate equipment in a safe manner taking into consideration all of the below requirements: Details of the lift, location and associated risk/hazard. Documented for any HSE, Permit to Work (PTW) and verification requirements, mainly for Non-Routine Simple & Non-Routine Complex. A toolbox talk (TBT) is conducted prior to any lifting operation being undertaken. Executed with certified equipment and personnel (Rigging supervisor, crane operator and a minimum of two riggers) and shall have valid certificates available, under the supervision of a QP approved competent person. For fixed crane operation lifting plans shall be submitted to QP Competent Person (LE) for one-off acceptance. For cargo loading/ offloading in ports, offshore platforms and rigs, lifting plans shall be submitted to QP Competent Person (LE) for one-off acceptance. Relevant calculations supporting the safety limits of operation shall consider the effects of dynamic loading and weather conditions. The estimation of the load shall include the weight of hook block, weight of all lifting gear and the weight of the wire rope below boom tip. When a load is to be lifted using the main hook, whilst the fly jib is installed, the weight of the fly jib and the fly hook shall be deducted from the lifting capacity of the main hook. The crane configuration such as boom length, height of lift, radius and available capacity for the intended lift and actual load to be handled at that configuration shall be clearly stated in the plan. The factor of safety (FOS) to be calculated and stated in the lifting plan. The compactness of the ground or foundations shall be assessed such that the crane can operate within level at all times. The bearing pressure shall be calculated by the civil engineer taking into account the dead weight of the crane, weight of the load, and any other dynamic factors and shall not exceed the bearing capacity of the supporting ground or foundations. In case of off shore transport of danger goods, danger goods lifting and operations must comply with the requirements of International Maritime Organization (IMO 2020), As a minimum the following shall be clearly identified; Clear marking of danger goods. Provision of relevant documentations of the type of hazardous material. SECURITY CLASSIFICATION: INTERNAL Page 7 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Risk associated with hazardous materials. A clear copy of the OEM’s crane capacity chart (in metric units and English language) shall be available. Specific Requirements For Control Of Non-Routine Simple And Complex Lifts A lifting plan/method statement, including a duly completed Form 1, (see Appendix E), shall be prepared by a competent person and submitted to a QP Competent Person (LE), at least 10 working days in advance, for approval prior to undertaking the operation. The details of the plan shall cover the following as a minimum: Job hazard analysis (JHA) / job safety analysis (JSA), address all the foreseeable risks and identify the control measures, so that the lifting operation is performed safely and logically. For onshore lifting operations, lifting appliances (crane) with a capacity of 25% above the maximum estimated weight of the load to be handled at as-rigged configuration shall be selected for the lift. For offshore lifting operations, lifting appliances (crane) safety factor to be calculated as per Dynamic Amplification factor (DAF) in accordance with the following table : TABLE 1: DYNAMIC AMPLIFICATION FACTOR SHL (Static Hook Load) DAF (Offshore) Up to 300 tonne (t) 1.25 300-1000 t 1.20 1000-2500t 1.15 > 2500 t 1.10 Lifting gear with a capacity of 30% above the maximum estimated weight of the load shall be handled as-rigged configuration, for the intended lift. The plan shall ensure that there is adequate site access for safe operation of the LE. Consideration shall be given to safe positioning of the outriggers or crawlers. 3.12 RESTRICTIONS FOR LIFTING OPERATIONS Restrictions For All Lifts The operation of cranes shall be suspended immediately in the event of adverse weather conditions such as storms, high sea states, strong winds, heavy rains, dust or fog or poor light impairing the visibility, in addition to OEM recommendations. Demarcation of, and any special precautions taken to maintain, a safe working area to prevent entry of unauthorized personnel to the site. SECURITY CLASSIFICATION: INTERNAL Page 8 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Restrictions For Non Routine Simple & Non-Routine Complex Lifts Cranes above 10 years of age used for Non-Routine Simple & Non Routine Complex lift shall be assessed by a QP Approved Inspection Service Provider on a case-by- case basis during the submission of lifting plan for acceptance and approval. Please refer to QP Corporate Procedure for Lifting Equipment Doc. No. QP-PAI-PRC-004. 3.13 INCIDENT REPORTING AND INVESTIGATION The objective of incident reporting and investigation is to prevent similar or associated incidents occurring in future. All incidents related to LE and LE personnel shall follow QP’s Corporate Standard for HSE Incident Reporting, Investigation and Learning QPR-STM- 001. VALIDITY PLAN This standard is effective immediately after its publication. For any grace period or transition, please approach Corporate HSE&Q department. REFERENCES TO OTHER DOCUMENTS The OEM’S manuals and technical literature shall be available. The applicable standards, detailed in Table 2, specify the minimum design, manufacture, installation, operation and inspection requirements acceptable to QP against identified items of LE. In the event of conflict between this standard and the standards referenced in Table 3 or the OEM manuals and technical literature, the most stringent requirements shall apply. Unless specifically approved, in writing, by Corporate HSE & Q Department. Acceptance of using other standards is subject to Corporate HSE & Q Department approval based upon providing detailed justification by the requesting party. Metric weights and measurements, as per the International System of Units (SI System) shall be utilized in all LE activities. The charts and tables of existing LE, which have been supplied with imperial units, shall be converted in accordance with the requirements of BS 350 Conversion factors for units, and shall be approved by a QP Approved Inspection Service Provider. It is the responsibility of the concerned QP Department and the contractor to ensure that this standard and other relevant standards as detailed in Table 2 and Table 3 are available. In addition, it is the responsibility of the respective operations management to ensure that the LE personnel are fully aware of the requirements of referenced standards and any amendments that may be periodically issued. All QP approved inspection training service providers shall have been accepted in accordance with QP requirements as detailed in QP-STD-Q-011 - QP Standard for Accepting Lifting Equipment Inspection, Testing and Certification SECURITY CLASSIFICATION: INTERNAL Page 9 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Contractors and Lifting Equipment Personnel Training and Certification Contractors. All formats for certification shall, as a minimum, contain all the details as shown in the sample formats contained in QP Corporate Procedure for Lifting Equipment Doc. No. QP-PAI-PRC-004. TABLE 2: REFERENCES TO OTHER INTERNAL DOCUMENTS Internal/External Document Document Name Document Number Document (if any) Referencing QP Procedure for Lifting QP-PAI-PRC-004 Internal Sideways Equipment Corporate Philosophy for QP-PHL-S-001 Internal Upward Fire and Safety Corporate Integrated Management System QP-IMS-MAN-01 Internal Upward Manual QP Standard for HSE Incident Reporting, QP-HSE-STD-021 Internal Sideways Investigation & Learning Standard for Fitness to QP-OHH-STD-011 Internal Sideways Work Guideline for SIMOPS QP-GDL-S-069 Internal Sideways Study Standard For Occupational Health, Safety, QP-STD-S-024 Internal Sideways Environmental and Quality (HSE&Q) Training Standard for Accepting L E Inspection, Testing and Certification Contractors QP- STD-Q-011 Internal Sideways and LE Personnel Training and Certification Contractors Corporate Standard for QP-STD-R-008 Internal Sideways NDT Corporate Standard for Quality Requirements for QP- STD-Q- 004 Internal Sideways Projects QP HSE Regulation for QP-REG-S-001 Internal Sideways Contractors SECURITY CLASSIFICATION: INTERNAL Page 10 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. 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QP-PAI-STD-005 REV.00 TABLE 3: REFERENCES TO OTHER EXTERNAL DOCUMENTS LE AND FPE TYPE BRITISH STANDARDS OTHER REFERENCES ‘A frame’ / Portable Gantry BS 7121-2-7 LOLER Beam Clamp BS EN 13155 LOLER & ASME B30.20 Bundle Puller and its Lifting Points -------------------- LOLER/ DNV 2.7-3 Cargo Net BS 6756 Manual Chain Hoist BS EN 13157 ASME HST-2 Chains for Lifting BS EN 818-1, -2, -3 & -7 ISO 7592 Chain Sling BS EN 818-4, -5 & -6 ASME B30.9 & ISO 7593 Cargo Carrying Unit (CCU) BS EN 12079-1, -2 & -3 DNV 2.7-1, -2 & -3, ISO 10855-1,2&3 Cable Pulling Machine BS EN 14492-1 Crane (Derrick) BS 7121-2-3 & BS EN 13001-1 ASME B30.8 & ASME B30.6 Crane (Electric Overhead Travelling, ASME B30.2, ASME B30.11, BS 7121-2-7 ASME B30.17 & ASME Monorail and Underhung, Gantry) B30.24 Crane (Floor/Manually Operated) BS 5744 & BS 7121-2-1 ASME PASE Crane (Lorry Loader) BS 7121 Part 4 & BS 7121-2-4 ASME B30.5, ASME B30.22 Crane (Mobile) BS 7121-2-1 & 3 ASME B30-5, PCSA STD No. 4 & SAE - J987 Runway Beams/Monorails BS 2853 ASME B30.16 Crane (Offshore) BS 7121 Part 11 & BS EN 13852- API Spec 2C & API RP 2D 1&2 ASME B30.4 for Onshore & Crane (Pedestal) -------------------- API Spec 2C for Offshore Crane (Portal Jib) BS 7121-2-7 ASME B30.4 Crane (Slewing Jib) BS 7333 -------------------- Crane (Slewing Jib Power Driven) BS EN 14985 -------------------- Beam Trolley BS EN 13157 ASME B30.17 Crane (Side Boom) BS 7121 Part 14 ASME B30.14 & ISO 8813 Crane (Stacker) -------------------- ASME B30.18 Crane (Tower) BS 7121- 5 & BS 7121-2-5 ASME B30.3, B30.29 Cranes - Training of Crane Operators and UK HSE Guidance Note BS 7121 Part 1 GS39. API RP 2D, ISO Slingers 23853:2018 Cranes Safety, General Design, Load BS EN 13001-1 & BS EN 13000 DIN 15019-1 & -2, ISO 4310 Actions Cranes Steel Structures Analysis BS EN 13001-3-1 DIN 15018- 3 Cranes: Testing of Installations – -------------------- DIN 15030 Acceptance Davit (General Purpose) BS MA 41 -------------------- Diving Operations Associated LE IMCA Guidelines SECURITY CLASSIFICATION: INTERNAL Page 11 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 LE AND FPE TYPE BS STANDARDS OTHER REFERENCES Earth Moving Machinery with Lifting BS EN 474 All parts PCSA standard No.3 Attachment BS 6911 parts 1, 6, 7, 8, 9, 10 &12 Eye Nuts -------------------- DIN 582 Eyebolt BS 4278 ASME B30.26 & ISO 3266 Fork Arms for Forklifts BS ISO 2330, BS 5639-1, ISO ------------------ 2331 Forklift /Telehandler BS EN 1459 & BS ISO 22915- ANSI B56.1,5&6 1&2 Frames/Skids for Transportation of BS EN 12079-1, -2 & -3 DNV 2.7-1, -2 & -3, ISO equipment 10855-1,2&3 BS EN 526, BS EN 14206 & LOLER, SOLAS & Gangway BS MA 78 IMO-MSC.1/Circ. 1331 Grabs BS ISO 20663 ASME B30.20 & LOLER Hoist (Powered) BS EN 14492 -2 ASME B30.7 Hoist Ring, Links, Swivels BS EN 1677-4 ASME B30.26 Hoists Overhead (Underhung) BS 7121-2-7 ASME B30.16 ASME B30.10, ISO 7597 & Hook BS EN 1677-1, 2, 3, 4 & 5 ISO 8539 Hopper BS 1703 LOLER Hydraulic Jacks BS EN 1494 ASME B30.1/ ASME PASE Jumbo Bag BS EN ISO 21898 Lever Hoist BS EN 13157 ASME B30.21 Lifeboat /Rescue Boat Lifting Frame -------------------- LSA Code & SOLAS Lifeboat /Rescue Boat Davit -------------------- LSA Code & SOLAS Lifeboat /Rescue Boat Lifting Points -------------------- LSA Code & SOLAS Lifting bag systems for fire and rescue BS EN 13731 service only Lifting Points for Walkway, Stairs and BS 5395 – 1, 2, 3 & 4 LOLER & ISO 14122-2 Ladders ISO 4190-2, ISO 4190-3, BS EN 81 – 50 & BS EN 81 – Lifts (Passenger or Goods) ISO 7465, ASME A17.1, 20 17.2, 17.3 & 17.4 Lifts (Service) BS EN 81 – 80, BS 7212 ISO 4190-5, -6 & ISO 7465 BS EN ISO 7500-1 & Load Cell and Test Machines ASTM E 74-13a BS EN ISO 376 Loading Ramp -------------------- ASME-PALD Man-Riding Basket/Personnel Carrier BS EN 14502 – 1 -------------------- Mast Climbing Working Platform BS EN 1495 -------------------- Material Hoist (mast) BS EN 1495 ANSI A10.5 Mobile Elevating Working Platform (MEWP) BS EN 280 ASME A120.1 & ASME B30.23 Pad Eyes (Fabricated) -------------------- DNV2.7-1 & -3 Pallet BS ISO 6780 -------------------- Pallet Forks BS EN 13155 SECURITY CLASSIFICATION: INTERNAL Page 12 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 LE AND FPE TYPE BS STANDARDS OTHER REFERENCES Pallet Stacker BS ISO 22915-4 -------------------- Pallet Truck – Hand Operated BS ISO 509 & BS EN ISO -------------------- 3691-5 Personnel Protective Equipment Against Fall BS EN 341, 354, 355, 358, ANSI Z.359.1, ANSIA10.32, From Height and Rescue Devices 360 TO 364 & 1496 OSHA 1926.502 Personnel Transfer Net -------------------- Billy Pugh Practice Pipe Clamp/Hook BS EN 13155 LOLER & ASME B30.20 Pulley Blocks BS EN 13157 ASME B30.26 Rules for Design of Cranes BS 2573-1 -------------------- Runway Beam BS 2853 -------------------- Safe Load Indicators BS 7262 ISO 10245 Part 1 to 5 Safety Net BS EN 1263-1 & -2 OSHA 1926.105 Shackle (Alloy steel ) BS 3551 US-FED.SPEC-RR-C-271 Shackle (Forged steel) BS EN 13889 -------------------- Skip (Baskets, Toolboxes, Cylinder Racks) BS 12079 Part 1 LOLER, ISO 10855-1,2&3 Snatch Block BS EN 13157 ASME B30.26 Spreader Beam/Bar/Frame BS EN 13155 LOLER & ILO TABLE Suspended Access Platform BS EN 1808 -------------------- Textile Sling (Round Sling/Webbing Sling) BS EN 1492-1, 2 & -4 ASME B30.9 Tirfors/Jaw Winch BS EN-13157 -------------------- Trunnion BS ISO 10276, BS EN 12574-1 ISO 10276 Turnbuckle and Rigging Screws BS 4429 ASME B30.26 Vehicle Lift BS EN 1493 ASME PASE Vehicle Mounted Drilling Rig BS EN 16228 ISO 18758-2 Water bag -------------------- LOLER Winch (Hand Operated Plate Sided) BS EN 13157 -------------------- Winch (Lifeboat and Man-Riding) -------------------- LSA Code & DNV-OS-E101 Winch (Powered) BS EN 14492-1 ASME B30.7 Wire Rope (Steel) BS EN 12385-1 to -10 API Spec 9A & ISO 4309 Wire Rope Sling (Steel) BS EN 13414-1 to -3 ASME B30.9 Wire Rope, Care and Use -------------------- API RP 9B In all instances, users of this Standard shall refer to the latest approved version of the above standards and references. The latest approved versions are as posted on QP Intranet under Engineering Services Department. SECURITY CLASSIFICATION: INTERNAL Page 13 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 DEFINITIONS TABLE 4: KEY TERMS DEFINED Term Definition Alteration/Major A measure whereby the original state of an appliance will repair be altered or restored by rebuilding or exchanging parts. All alterations must be approved, in writing, by the Original Equipment Manufacturer (OEM). Major repair criteria shall be as defined by the OEM or relevant standard. Authorised Person authorised by the QP Approved Inspection/Training Signatory Service Provider to check and sign certification. Certification Any activity related to LE and LE personnel where it is necessary to obtain a certificate, signed by a QP Approved Inspection/Training Service Provider. Colour Coding A designated system applied by QP to mark all LE according to the scheduled inspection period, to clearly indicate of its certification status. The colour code is valid for six (6) months. Competent Person A person having practical, theoretical and legislative knowledge and relevant experience sufficient to enable that person to perform his/her duties safely. Crane Footprint The hemispherical boundary created by a radius of 1.1 x the maximum crane boom length. Dynamic Factor The factor by which the gross weight is multiplied, to account for accelerations and impacts during the lifting operation. Factor of Safety It is a factor that is applied to the minimum breaking Load (FOS), Coefficient of (MBL) to determine the SWL or WLL. It varies with the Utilisation or product to take account of the susceptibility to damage and Working Coefficient considers the type of stresses the item will meet in normal use. Fall Protection A generic term used to cover PPE that protects personnel Equipment (FPE) from falling whilst working at height. Lifting Appliances Any manual or powered lifting machine, that is able to (Lifting Machines) raise, lower or suspend loads, and includes the supporting structure and all equipment and gear used in connection with such a machine, including earth moving machines with lifting attachments. SECURITY CLASSIFICATION: INTERNAL Page 14 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Term Definition Lifting Equipment A generic term used to cover lifting appliances, lifting gear (LE) and fall protection equipment (FPE). LE shall mean any equipment for lifting or lowering loads, and includes its attachments used for anchoring, fixing or supporting it. It includes any lifting accessories that attach the load to the lifting machine in addition to the equipment that carries out the actual lifting function. Lifting Gear (Lifting Any item used to connect a load to the lifting appliance but Accessories or which is not in itself a part of the load or the appliance. Loose Gear) Lifting Plan Documented details how the lifting operations shall be undertaken, the LE and lifting accessories to be used, how the equipment and lifting accessories shall be rigged up and the control measures in place to manage the risks. Load Any material, personnel, or any combination of these that are lifted, lowered or suspended by the LE. The weight of the lifting accessories including the hook block shall be considered as part of the load being lifted. Minimum Breaking The minimum breaking load is the load at which an item is (or Failure) Load expected to break or fail. (MBL) Mode Factor A factor applied by the user that takes into account the geometry of a sling assembly to obtain the maximum load that may be lifted for a particular mode of use or a configuration of use. Original Equipment The OEM is the person or legal entity that has the legal or Manufacturer (OEM) patent rights to produce the material, component, product or system. Proof Load Test Deliberate application of a predetermined load in excess of (PLT) SWL to assess the ability of the equipment to withstand operational requirements. QP Approved It is the LE Inspection and Certification Provider accredited Inspection Service by either, member of International Accreditation Forum Provider (IAF), International Laboratory Accreditation Cooperation (ILAC) or any other QP accepted equivalent or accredited by a Conformity Assessment Body (CAB) that is accredited by IAF, ILAC or any other QP approved equivalent and accepted by QP Corporate HSE&Q to inspect, test and certify LE. SECURITY CLASSIFICATION: INTERNAL Page 15 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Term Definition QP Approved It is the LE Training and Certification Provider accredited by Training Service either, member of the IAF, ILAC or any other QP accepted Provider equivalent or accredited by a CAB that has been accredited by IAF or ILAC or any other QP approved equivalent and accepted by QP Corporate HSE&Q to train and certify LE personnel. QP Competent A QP Employee, having practical, theoretical and Person (LE) legislative knowledge and relevant experience sufficient to enable that person to perform his/her duties safely. Safe Working Load The maximum load, as certified, that an item of LE may (SWL) raise, lower or suspend under particular service conditions. It is the SWL that is marked on the item and that appears on any examination report or test records. Toolbox Talk (TBT) It is the final check in the hazard assessment process and the start of the implementation of the work where Risks and emergency preparedness/ response requirements attended by everyone involved in the lifting operation at the work site, covering the work plan, the hazards, the controls, roles and responsibilities, and any recovery measures to be taken if the controls are not completely effective. Working Load Limit The maximum load that an item of LE is designed to (WLL) sustain, i.e. to raise, lower or suspend incorporating an appropriate FOS. SECURITY CLASSIFICATION: INTERNAL Page 16 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 APPENDIX APPENDIX A - COMPETENCE REQUIREMENTS FOR QP/CONTRACTOR LE PERSONNEL A.1 QP COMPETENT PERSON (LE) SHALL MEET THE FOLLOWING REQUIREMENTS: Hold a Degree/Diploma in engineering. Certified by Lifting Equipment Engineers Association (LEEA), Foundation and Lifting Equipment General (LEG). For degree holders, shall have a minimum of five (5) years’ experience in any engineering field (preferably LE) of which three (3) years has been spent in inspection and certification of LE. For diploma holders, shall have a minimum of eight (8) years’ experience in any engineering field (preferably LE) of which three (3) years has been spent in inspection and certification of LE. Familiar with international LE standards and codes for inspection, testing and certification. A.2 QP ACCEPTED LE INSPECTORS/SURVEYERS AND QP ACCEPTED LE PERSONNEL TRAINERS SHALL MEET THE FOLLOWING REQUIREMENTS: Hold a Degree/Diploma in engineering. Certified by LEEA, LEG and any other part or equivalent. For degree holders, shall have a minimum of five (5) years’ experience in any engineering field (preferably LE) of which three (3) years has been spent in inspection and certification of LE after LEEA certification. For diploma holders, shall have a minimum of eight (8) years’ experience in any engineering field (preferably LE) of which three (3) years has been spent in inspection and certification of LE after LEEA certification. Familiar with international LE standards and codes for inspection, testing and certification. LE Inspector/Surveyor performing inspection and certification activities shall be authorised by a QP Approved Inspection Service Provider for performing inspection and certification LE Trainers performing LE personnel training and certification activities shall be authorised by a QP Approved Training Service Provider for performing LE personnel training and certification. LE Trainers performing LE personnel training and certification activities shall be approved as a trainer by completing a ‘train the trainer’ course conducted by any of the internationally recognized training institutes and having 3 years teaching experience related to LE. A.3 QP ACCEPTED LE CERTIFICATE AUTHORISED SIGNATORY SHALL MEET THE FOLLOWING REQUIREMENTS: Hold a Degree/Diploma in engineering. Certified by LEEA, LEG and any other part. SECURITY CLASSIFICATION: INTERNAL Page 17 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Have a minimum of eight (8) years’ experience in any engineering field (preferably mechanical) of which five (5) years has been spent in inspection and certification of LE. Familiar with LE and FPE and international LE and FPE codes and standards for performing inspection, testing and certification. Authorised by a QP Approved Inspection Service Provider/QP Approved Training Service Provider as an authorised signatory on LE and FPE and personnel certification. Authorised signatory shall not be the Inspector/Surveyor of the issued certificate. A.4 OPERATORS: CRANE, FORKLIFT, MEWP, TELEHANDLER AND BUNDLE PULLER SHALL MEET THE FOLLOWING REQUIREMENTS: A.4.1 PHYSICAL AND EDUCATION QUALIFICATIONS Have a minimum of three (3) years’ experience. Capable of reading and understanding the English language sufficient for communication and the fulfilment of their function in a safe manner. Certified physically and medically fit, including eyesight, colour blindness, hearing and reflexes, by a Qatar registered medical practitioner. A.4.2 TRAINING AND CERTIFICATION REQUIREMENTS Hold the appropriate current and valid Qatari driving license as applicable. Hold a valid certificate of competence issued by a QP Approved Training Service Provider and accepted by a QP Competent Person (LE). Hold an identification card with photograph issued by a QP Approved Training Service Provider. Only use equipment for which they have received training. Initial QP Approved Training Service Provider training shall be for a minimum of three (3) days. Refresher QP Approved Training Service Provider training shall be for a minimum of two (2) days. Validity of the certificates shall not exceed three (3) years. A.5 RIGGING SUPERVISOR SHALL MEET THE FOLLOWING REQUIREMENTS: A.5.1 PHYSICAL AND EDUCATIONAL QUALIFICATIONS At least 30 years of age and physically fit. Educated to a minimum secondary level. Have a minimum of eight (8) years rigging experience in the lifting activities, with at least three (3) years supervisory experience. Capable of reading, speaking, writing and understanding the English language. Have strong administrative and supervisory skills to schedule, monitor and control the LE personnel and lifting operations. Certified physically and medically fit, including eyesight, colour blindness test, hearing and reflexes, by a Qatar registered medical practitioner and/or QP owned medical centres. SECURITY CLASSIFICATION: INTERNAL Page 18 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 A.5.2 TRAINING AND CERTIFICATION REQUIREMENTS Attend a pre-course assessment conducted by a QP Approved Training Service Provider. Successfully complete a training course, minimum duration five (5) days for initial training and three (3) days for refresher training, conducted by QP Approved Training Service Provider. Hold an identification card with photograph issued by QP Approved Training Service Provider. A.6 RIGGER SHALL MEET THE FOLLOWING REQUIREMENTS: A.6.1 PHYSICAL AND EDUCATION REQUIREMENTS Minimum 21 years of age. Experienced in rigging for a minimum of three (3) years. Capable of reading and understanding the English language sufficient for the fulfilment of their function in a safe manner. Certified physically and medically fit, including eyesight, colour blindness test, hearing and reflexes, by a Qatar registered medical practitioner. A.6.2 TRAINING AND CERTIFICATION REQUIREMENTS Hold a valid certificate of competence issued by a QP Approved Training Service Provider or an internationally recognised body acceptable to QP Approved Training Service Provider and accepted by a QP Competent Person. Hold an identification card with photograph issued by a QP Approved Training Service. Marine divers, crew and all seafarers handling LE shall undergo Rigging training and shall have a valid Rigger certificate of competence. The validity of QP Approved Training Service Provider certificates shall not exceed three (3) years. Initial and refresher QP Approved Training Service Provider training shall be for a minimum of three (3) days. SECURITY CLASSIFICATION: INTERNAL Page 19 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 APPENDIX B - REQUIREMENTS FOR LIFTING APPLIANCES B.1 GENERAL Subsequent to thorough and visual examination, if defects are evident, the QP Approved Inspection Service Provider may give instructions to perform further tests, examinations, NDT, etc. at his discretion to assess the integrity of the equipment. All lifting appliances shall be designed, engineered, constructed, installed, tested, operated and maintained in accordance with the specified standards and this standard. All lifting appliances shall be assigned unique identification numbers and marked with certified SWL. In addition all items shall be colour coded in accordance with the QP colour coding scheme, which is applicable at the time of utilisation. The contractor shall ensure that the equipment bears the current colour coding according to the period specified in the QP colour coding schedule. A comprehensive register of LE detailing the following minimum information shall be developed for monitoring periodic inspection requirements. Table 1: LE REGISTER Equip Date of Due Date of Date of Brief Description Due Date of SWL Proof Load next Proof Load ID No. of Equipment Inspection next Inspection Test Test The LE Focal Point for the Operational Area shall take delivery of new LE and fall protection equipment. No lifting appliance shall undergo alterations to components or parts that affect its structural integrity or load bearing capacity without the written approval of the OEM. When any lifting appliance has undergone repairs that affect the load bearing parts or replacement of parts or components that affect the structural integrity, the lifting appliance shall be re-inspected, proof load tested and certified by a QP Approved Inspection Service Provider. Safety devices that affect the integrity of a lifting appliance shall not be altered without the written approval of the OEM. Where a lifting appliance has suffered major damage or incident, the appliance shall not be repaired without a written repair procedure from the OEM, and shall be retested after the repairs by a QP Approved Inspection Service Provider to verify the equipment structural integrity. Any lifting appliance, that has been newly installed or relocated, shall undergo approval by QP Approved Inspection Service Provider and commissioning tests shall be performed before being used. A complete manufacturer’s maintenance and operating manual for lifting appliances shall be available for reference to the operator and maintenance personnel at site/location. The lifting appliance shall be operated and SECURITY CLASSIFICATION: INTERNAL Page 20 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 maintained in accordance with the procedures set out in their relevant handbook and manuals. All cranes permanently installed in a location that has slewing limitations or crane boom restrictions (i.e. jack-up rigs or barges) due to structural design (i.e. legs), shall be fitted with an approved and maintained limiting device, in accordance with the relevant standards. In addition to the statutory thorough examinations by a QP Approved Inspection Service Provider, the lifting appliance operator is responsible to complete regular in-service visual inspections, before each shift and before lifting a load, in accordance with the lifting appliance OEM’s recommendation, to identify any faults and damage that might arise. If any are found they should be referred to a QP Competent Person (LE). Contractors providing services, construction, inspection and maintenance, to QP shall insure that cranes utilised in lifting operations are adequately covered by insurance. B.2 REQUIREMENTS FOR ALL CRANES: B.2.1 GENERAL All cranes shall have the following: Operating levers and switches that are clearly identified and marked. All markings shall be in English or internationally agreed symbols. Check valves or holding valves shall be fitted to all hydraulic cylinders to prevent cylinder movement in the event of hose failure. A facility for emergency lowering of loads. An emergency stop with manual re-set capability within crane operator reach. Motion control levers that return to neutral with a minimum delay upon release (this does not apply to engine throttle lever). An emergency escape route for personnel. Safety latches that automatically close fitted to all integral crane hooks. A suitable operating cab, as and when applicable, that adequately protects the crane operator and controls from the elements (weather), is adequately cooled (if possible) and ventilated, and provides a clear and unrestricted view of all operations associated with the crane. The SWL of the hook block prominently marked and highlighted on the hook. Maintenance and repair logbook for each crane and such is to be maintained. Audible and visual alarm fitted on crawler cranes while travelling forward or reversing. The load bearing components or structures of the crane shall be subjected to Magnetic particle Inspection or any other suitable NDT examination at the discretion of the QP Approved Inspection Service Provider following a Proof Load Test (PLT). An adequate and certified portable fire extinguisher within the crane operator reach. Rated capacity limiters and indicators on all cranes, excluding Electric Overhead Traveling (EOT) cranes having a rated capacity of three (3) tons and above. SECURITY CLASSIFICATION: INTERNAL Page 21 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 A checklist based on the manufacturer’s instructions covering the assembly and erection of the crane shall be used during dismantling and erection at site. The erection of the crane shall be performed by competent persons. B.2.2 OPERATIONAL RESTRICTIONS No person shall be transported by a crane except in an approved workbasket or personnel transfer net. The operator shall not leave the controls while the personnel or load is suspended. All cranes utilised at jetties for handling loads shall have a legible metric load chart that has been calculated in accordance with the dynamic factor (load factor) of 1.35 or as recommended by the crane manufacturer, permanently fixed in the crane operator’s cabin. Cranes shall not be used to transport loads unless they are specifically designed for the purpose. No crane is allowed to pull or tow weights. No crane is allowed to enter any hazardous zone without permission and verification of zone requirement. Cranes shall not be utilised when the wind speed is more than 25 knots or exceeds values set out by the OEM of the crane, whichever is lesser. Use of cranes above 25 knots can only be considered on a case-by-case basis via a waiver request, subject to a detailed risk assessment supported in writing by the OEM’s certified maximum safe operating wind speed. Under no circumstances are lifting operations permissible in wind speeds in excess of OEM certified maximum safe operating wind speed. All lifting operations above 25 knots require a written acceptance by a QP Competent Person (LE). Cranes shall not be utilised to carry out any lifting operations during periods of poor visibility. Any lifting operations that have to be performed after sunset or during periods of poor visibility, shall be with the full approval of QP/HSE operational and Projects departments.Adequate illumination shall be provided to ensure all involved persons and equipment are clearly visible when carrying out the lift. In addition the LE shall have its own means of illumination to ensure that the operator at all times can see adequately what actions are taking place and the crane itself shall be fitted with lights at all extremities and along the length of the boom where feasible to assist all personnel involved in the operation can be aware of any movement of the crane. B.2.3 ADDITIONAL REQUIREMENTS FOR CRANES USED FOR LIFTING PERSONNEL IN SUSPENDED MAN-BASKETS Cranes shall have a Safe Load Indicator (SLI) with an appropriate duty for lifting personnel (i.e. half the rated capacity for lifting other loads). For cranes that do not have the above, the crane shall be derated and used to 50% of its rated capacity chart. Shall have a rope spooling device, if originally supplied with one by the OEM. The crane shall automatically stop all motions when the controls are released. The crane shall be equipped with anemometer. The crane shall be equipped with a winch that has power lowering. Cranes with free-fall ability shall not be used for personnel lifting, unless the free-fall facility has been locked out. SECURITY CLASSIFICATION: INTERNAL Page 22 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Load bearing hydraulic cylinders fitted with load hold valves shall stop movement of the crane in case of hose rupture or pipe fracture. The crane control shall be such that the man-basket can move gently and the working speed shall not exceed 0.5 m/s on all motions. The crane should not be used to lift persons in wind speeds in excess of 7 m/s. The crane shall have a control mechanism to lower the man-basket to a safe position, in a controlled manner, in the event of power failure or crane’s control failure. The operator shall be familiar with this control mechanism. The wire rope used for hoisting and lowering the man-basket shall have a minimum diameter of 8 mm and above. Cranes shall be inspected and certified by a QP Approved Inspection Service Provider for the above items. B.3 MOBILE CRANES: On initial supply if the crane has been tested and certified to 125% of SWL and witnessed by a QP Approved Inspection Service Provider, no further initial PLT is required. Ground conditions shall be risk assessed before deploying the crane outriggers. Crane pads with a minimum size of 1.5 square meter shall be used to help disperse weight evenly under each of the cranes outriggers. B.3.1 SIX (6) MONTHLY THOROUGH INSPECTION OF MOBILE CRANES Telescopic booms/fly jibs shall be thoroughly and visually inspected on all sides, section by section, in its extended/erected condition. Telescopic boom wear pads are to be checked for their condition. Lattice boom shall be lowered on the boom support cradles for thorough examination. The main and auxiliary hoist, boom and pendant wire ropes etc. shall be thoroughly inspected throughout their complete length. Cross reference against wire rope certificate to ensure correct construction and diameter fitted and verified against OEM requirements. Automatic digital SLI system shall be checked and verified against known weights for all the parameters. Safety devices such as overload cut-off system, anti-two block, jib hoist cut-off, working area control devices, boom locking system, and winch drum locking devices, etc. shall be checked for their correct functioning. Condition of the slewing machinery system including slewing gear, bearing, slewing brake, slewing lock etc. shall be checked. Hook block sheaves/boom head sheaves shall be thoroughly inspected to ensure that there are no visible cracks or any damage. Counterweight locking pins/bolts shall be checked for correct anchorage. The required number of counterweights shall be fitted on the crane in compliance with the load chart. The crane maintenance logbook shall be verified for any evidence of repairs or any maintenance work performed. Whenever considered necessary by a QP Competent Person (LE), NDT shall be performed on cranes components. SECURITY CLASSIFICATION: INTERNAL Page 23 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 B.3.2 ANNUAL THOROUGH INSPECTION AND TESTING OF MOBILE CRANES (IN ADDITION TO B.3.1) At least three (3) 100% SWL tests shall be performed in accordance with load chart and crane rating at different boom length configuration, (shortest boom possible, intermediate boom and longest boom), at appropriate radii. All test certificates for cranes shall have crane capacity charts attached for verification. B.3.3 PLT OF MOBILE CRANES (IF REQUIRED) Records of any major repairs or replacements shall be verified before commencing the tests. At least three (3) tests shall be performed in accordance with load chart and crane rating at different boom length configuration, (shortest boom possible, intermediate boom and longest boom), at appropriate radii. All safety switches shall be checked for correct operation. Any safety switch overridden during the test shall be re-set and checked for correct functioning after the load tests. All test certificates for cranes shall have crane capacity charts enclosed for verification. Crane with extendable fly jib installed requires at least two (2) 100% SWL tests at shortest and longest fly jib length, after every reinstallation. These tests shall be performed in accordance with load chart and crane rating, at appropriate radii. Crane with fixed fly jib installed requires 100% SWL test after every reinstallation. B.4 OFFSHORE CRANES: B.4.1 GENERAL Onshore cranes shall not be used for offshore service unless confirmed by the OEM that the crane is suitable for offshore service. All cranes on vessels/barges, contracted, owned and/or operated by QP, which are not covered under the classification or competent authority recognized by the flag state, shall be inspected and certified to conform to this standard. B.4.2 ADDITIONAL REQUIREMENTS FOR OFFSHORE CRANES All offshore cranes shall comply with the following in addition to those as detailed within Section B.2. Have a readily accessible shutdown device in the air intake of any internal combustion engine. Have an exhaust equipped with a spark arresting device. Have fitted or access to, in close proximity (visible to the crane operator), a working and calibrated anemometer or be provided with a means of communication to the nearest station monitoring wind speed. Have a boom angle indicator and, where applicable, a boom extension indicator clearly visible to the Crane Operator. SECURITY CLASSIFICATION: INTERNAL Page 24 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Be fully and thoroughly inspected by a QP Approved Inspection Service Provider at a maximum of six (6) monthly intervals to ensure compliance with the relevant standards and this standard. QP Approved Inspection Service Provider shall witness 100% SWL test on a yearly basis as shown in Table 2, Appendix B. Be provided with hands free VHF radio or any communication system between crane operator, rigger, vessel’s captain and control room. B.4.3 SPECIAL RESTRICTIONS When a ship, barge drilling rig or pontoon fitted with LE is engaged in lifting loads and is counter-balanced to reduce heel or trim, the vessel’s stability shall be sufficient to absorb the full counter-heeling moment that would be imposed in the event of loss of the load and to provide an additional margin of stability. All ballasting arrangements shall be under the control of a competent person, qualified under International Association of Classification Society or marine warranty surveyor. Cranes shall not be utilised when the mean wave height exceeds two (2) meters. Under no circumstances are lifting operations permissible in wind speeds in excess of OEM certified maximum safe operating wind speed. Offshore cranes used for raising or lowering personnel must meet the requirements of API SPEC 2C Specification for Offshore Pedestal-Mounted Cranes and API RP 2D Recommended Practice for Operation and Maintenance of Offshore Cranes. If an offshore crane has not been designed for raising or lowering personnel, it shall not be used for this purpose. If an offshore crane is being used for raising or lowering personnel, the operation shall be suspended if the wind speed exceeds 12 knots. B.5 OVERHEAD TRAVELLING CRANES All overhead travelling cranes shall comply with the requirements of the specified standards, and in addition shall: Have positive end stops with resilient buffers installed for cross travel and long travel movement. Have limit switches for cross travel and long travel movement. Existing cranes which do not have limit switches, shall, if possible, be modified to include them. Have anti-collision switches installed if more than one crane is operating on same rails. Have isolator switch at easily accessible position. Have audible warning device fitted for cabin-operated cranes. Pendant control (if fitted) to have emergency stop button. Have an overload limit switch system installed. Existing cranes, which do not have overload limit switches, shall, if possible, be modified to include them. Have prominent marking of SWL and ID number on the crane bridge. B.6 TOWER CRANES All tower cranes shall comply with the requirements of the specified standards. SECURITY CLASSIFICATION: INTERNAL Page 25 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Signboards, lights, etc. can impose additional loadings on the crane and shall not be fitted unless approved by the manufacturer. The following are minimum safety equipment that shall be provided on the crane: Automatic safe load indicator, Motion limiting devices, Overload cut-out devices, Anemometer, Zoning devices where there are two (2) or more cranes operating in the same area. Rail mounted tower cranes shall be fitted with an audible alarm while travelling. Jib counterweights and central ballast shall be in accordance with OEM and verified by QP Approved Inspection Service Provider prior to erection. A certified vertical wire rope lifeline with auto-locking shall be installed, in the absence of a fall protection cage, for climbing the vertical ladder. A certified horizontal wire rope lifeline along the boom shall be installed, in the absence of an inspection basket. B.7 LORRY LOADER CRANE Lorry loader cranes (telescopic boom with/without winch system) manufactured after 2014 shall have an inbuilt Rated Capacity Indicator (RCI). Lorry loader cranes (telescopic boom with/without winch system) manufactured before 2014 shall be fitted with either RCI or a device that shows the actual load. Lorry loader cranes shall be operated by a certified lorry loader operator. Lorry loader trucks shall be driven by a person holding a valid Qatar medium truck driving license. B.7.1 OPERATIONAL RESTRICTIONS Lorry loader cranes shall not: Pull or tow weights. Enter any dangerous zone without permission and verification of zone requirements. Move the vehicle with the outriggers in extended position. Move the vehicle with the boom in extended or raised position. Move the vehicle with the load on the crane (pick and carry is prohibited). Be operated on tyres without extending the outriggers. Use fuel like petrol and liquefied petroleum gas (LPG), in areas where there is a risk of a flammable vapour, gas or dust concentration being present. Lorry loader cranes with diesel engines shall only be used in potentially explosive atmospheres if, in addition to protection of the electrical system, the exhaust is protected against spark emission, precautions are taken against the intake of flammable mixtures and hot surfaces are protected. SECURITY CLASSIFICATION: INTERNAL Page 26 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 All lorry loader operations shall be halted where weather conditions are bad enough to adversely affect the performance of the lift truck or expose the operator to danger, e.g. excessive wind speed, poor visibility due to mist or fog, lightning or heavy rain. For conducting PLT annual certification and maximum pull per line details refer to Table 2, Appendix B. B.8 DAVITS (GENERAL PURPOSE) Davits (general purpose) are used throughout QP operational areas on many types of equipment. Use of the davit is normally determined by the type of equipment it is fitted to. Davits used infrequently (less than once a year), prior to use, shall have visual and functional test performed and recorded by asset owner. B.9 EARTH MOVING EQUIPMENT (WITH LIFTING ATTACHMENT) All earth moving equipment operators shall have a valid Qatar driving license suitable for the specific equipment they are operating. If the earth moving equipment is used as a lifting appliance then such equipment shall be certified by a QP Approved Inspection Service Provider and the operator certified by a QP Approved Training Service Provider for that specific equipment. B.10 ELEVATORS (PASSENGER AND CARGO) All elevators shall comply with the requirements of the specified standards and the OEM’s operation and maintenance manuals, and additionally: Drop test shall be limited to the initial supply or any subsequent major repair or failure. The number of persons permitted at one time inside the elevator and SWL shall be prominently displayed on all elevators. All elevators shall have a logbook in which the owner records the maintenance, safety checks and comments relating to the operation. B.11 ESCALATORS All escalators shall comply with the requirements of the specified standards and the OEM’s operation and maintenance manuals, and additionally: All escalators shall have a logbook in which the owner records the maintenance, safety checks and comments relating to the operation. B.12 FORKLIFT All forklifts including electrically/battery operated shall comply with the requirements of the specified standards and the OEM’s operation and maintenance manuals, and additionally: Forklifts shall be fitted with Qatar traffic registered plate number. QP asset owner on case-by-case basis shall approve permission for exclusion for this. Fork arms shall not be distorted or perforated. SECURITY CLASSIFICATION: INTERNAL Page 27 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 Forklifts shall not be used to lift loads unless the pneumatic tyres are inflated to the correct pressure. The inflation pressure for each tyre shall be shown prominently on the forklift. All forklifts shall be fitted with audible and visual warning devices, e.g. horn, reverse horn, front and rear lights and a flashing light on the top, to warn other personnel in the vicinity. Diesel-powered lift trucks shall only be used in potentially explosive atmospheres if, in addition to protection of the electrical system, the exhaust is protected against spark emission, precautions are taken against the intake of flammable mixtures and hot surfaces are protected. If any attachment, including man-riding basket, is fitted that may alter the characteristics of the forklift, a QP Approved Inspection Service Provider, in accordance with the OEM’s written recommendations, shall carry out the necessary de-rating and certification. The attachments shall be securely fastened and care taken to ensure that the attachments or securing device do not foul any part of the mast structure during raising or lowering of the attachment. The SWL shall be prominently displayed on all forklifts. No forklift shall be used beyond its statutory test period. All forklifts shall be fitted with seatbelts. All forklifts shall be fitted with adequate and certified portable fire extinguisher. B.12.1 OPERATIONAL RESTRICTIONS No forklift shall be used beyond its statutory test period. Forklifts shall not be driven on public roads. Forklifts shall not be used to lift a load greater than the maximum designed SWL at specific load centre. All lift truck operations shall be halted where weather conditions are bad enough to adversely affect the performance of the lift truck or expose the operator to danger, e.g. excessive wind speed, poor visibility due to mist or fog, lightning or heavy rain. Petrol and LPG-engine lift trucks shall not be used in potential fire/explosion risk hazardous areas. Suitably protected battery-powered and diesel forklift trucks shall only be used in potentially fire/explosion risk hazardous areas. Use of forklifts for transport of personnel is strictly forbidden. B.13 GRABS All grabs shall comply with the requirements of the specified standards and the OEM’s operation and maintenance manuals. B.14 JACKS (MOBILE OR PORTABLE) AND ASSOCIATED LE Jacks shall be designed or equipped in a way that the load can be restrained and held. All hydraulic and pneumatic jacks shall be fitted with security devices against overloading and these devices shall be set to the lowest possible value between 100% and 125% of the rated load. SECURITY CLASSIFICATION: INTERNAL Page 28 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 A pressure relief valve shall be fitted between the pump and the non-return valve and its allowed tolerance is between 100% and 125% of the rated load. The direction of motion shall be identified by symbols or words and shall be attached to the control device or immediately alongside it. The lift pad shall have a rough surface or be designed in such a way to counteract any tendency of the load to slip off. Jack operator shall hold a valid certificate of competence issued by a QP Approved Training Service Provider. B.14.1 OPERATIONAL RESTRICTIONS All jacks of mechanical type shall be replaced with a static support once the load has been lifted to the desired position. Every refillable hydraulic system shall have adequate means of filters to aid the proper and continued working of the safety devices. B.15 JAW WINCH (Tirfor) MANUAL CHAIN HOIST AND LEVER HOIST Subsequent tests for hoists fitted with ‘limited slip clutch’ shall be tested to the slipping load specified by the OEM. B.16 LE USED FOR DIVING OPERATIONS During diving operations, the following shall apply, in addition to the relevant International Marine Contractors Association (IMCA) requirements: Any crane when used in conjunction with diving operations shall have an audio alarm and visual device (e.g. mirror) indicating that there is a minimum of three (3) turns of wire rope left on the hoisting drums. Where diving operations are being performed, LE not associated with the diving operations shall not be operated or utilised if there are divers within the vicinity. During any diving operation where the use of submerged LE is required, adequate, uninterruptable and suitable voice communication between the diver(s), diving supervisor, crane operator and rigger shall be established. During any diving operation where the use of submerged LE is required, the LE shall be adequately and suitably illuminated or identifiable to the diver(s). The usage of any LE operated or utilised in submerged applications shall be registered in a logbook. The logbook shall be signed and dated on each occasion. On each and every occasion that LE is used, it shall be checked for adequacy and suitability, and after each use it shall be washed with fresh water and greased or protected as necessary. The wire rope shall be cut back to beyond the first sheave and be tested to destruction to prove the FOS every 12 months. None of the above actions relieve the duties of the Diving Supervisor and QP representative, whose responsibility is to ensure that the LE used during each and every dive is safe and adequate for the task. NOTE: For wire rope slings refer to Appendix C.3.19. SECURITY CLASSIFICATION: INTERNAL Page 29 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 B.17 MOBILE ELEVATED WORKING PLATFORM (MEWP) All MEWPs shall comply with the requirements of the specified standards and the OEM’s operation and maintenance manuals, and additionally: All MEWPs shall have an overload sensing device installed. All self-propelled MEWPs shall have Qatari registration plates. B.17.1 OPERATIONAL RESTRICTIONS MEWP operations shall not be performed with wind speeds in excess of 25knots. Personnel riding in the MEWP shall wear QP accepted and certified FPE and the safety harness shall be secured to the designated anchor point of the appliance. MEWPs shall not be operated in any overload condition. All MEWPs shall be operated by QP accepted and certified MEWP operator. B.18 PORTABLE GANTRY (A-FRAME) Any portable gantry having a single pad eye attached to it for lifting loads, the pad eye shall be tested to 1.25 x SWL of portable gantry. Any portable gantry having multiple pad eyes attached to it for lifting loads, all the pad eyes shall be simultaneously tested to 1.25 x SWL of portable gantry. After testing of pad eyes NDT shall be performed to ensure that all welds around the pad eye are free from any defects. Any portable gantry with a trolley and chain hoist shall be tested to 1.25 x SWL of the portable gantry. During testing deflection to be measured and be limited to Span/500. B.19 RUNWAY BEAM / MONORAIL Any trolley and chain hoist fixed on the runway beam / monorail shall be tested to 1.25 x SWL of the runway beam. Runway Beam / Monorail must be clearly identified with a separate colour, preferably yellow and have prominent marking of SWL and ID number. All Runway Beams / Monorail shall be fitted with end stoppers. If possible, runway beams / monorails shall be fitted with a lifting appliance of the same capacity. In case of any capacity variation the lower SWL to be assigned and marked accordingly. B.20 SIDE BOOM PIPE LAYER Side Boom Pipe Layers shall be fitted with an SLI with overload protection. In the absence of an SLI with overload protection the owner shall specify the means of load measurement. This shall be confirmed and detailed on the QP Approved Inspection Service Provider certificate. Side Boom Pipe Layer shall be driven or operated by a person holding a valid Qatar excavator or crane driving license and hold a valid certificate of competence issued by a QP Approved Training Service Provider. SECURITY CLASSIFICATION: INTERNAL Page 30 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 B.21 VEHICLE LIFT Locking mechanisms shall not be modified, unless confirmed in writing by OEM. Locking mechanisms shall be checked prior to every use. The control position to operate the vehicle lift shall be designed and arranged so that the operator can watch the load carrying device and the load whilst in motion, as well as the space under the load carrying device and the load. All vehicle lifts shall be equipped with an emergency stop device and it shall stop the motion of all the lifting devices immediately it is activated. The termination efficiency shall be a minimum of 80% of that of the wire rope MBL. Bulldog grips shall not be used for vehicle lift wire rope terminations. The MBL of chain used for chain drives shall be at least four (4) times the maximum possible static load, with the rated load in the most unfavorable position. Chain wheels and sprockets with undercut teeth shall not be used. All hydraulic and pneumatic jacks shall be fitted with security devices against overloading, and these devices shall be set to the lowest possible value between 100% and 125% of the rated load. The direction of motion shall be identified by symbols or words and shall be attached to the control device or immediately alongside it. Pulleys and wheels for ropes and chains shall be provided with derailment protection. This shall be designed such that the rope or chain cannot pass between the derailment protection and the pulley or wheel. All vehicle lifts shall be fully thoroughly inspected by a QP Approved Inspection Service Provider at a maximum interval of six (6) months for offshore and onshore locations. Use of vehicle lifts other than for their intended use is strictly forbidden. B.22 VEHICLE MOUNTED DRILLING RIG All vehicle mounted drilling rig operators who have to drive on roads shall have a valid Qatari driving license suitable for the equipment he is operating and hold a valid certificate of competence issued by a QP Approved Training Service Provider. All operating levers/switches/gauges shall be clearly identified and operable. Operator shall be safely protected at the operating panel area. Emergency stops to be fitted within operator’s reach. The ground conditions shall be assessed before deploying the outriggers which shall be marked with red and white chevron patters. The load bearing components, the mast structure, the drilling lifting capacity and the auxiliary single joint LE shall be PLT and inspected by a QP Approved Inspection Service Provider. Petrol driven engines are not allowed in QP fields. Diesel driven engines shall be certified for working in hazardous zones, fitted with automatic shut off valve (Chalwyn) on engine air intake and spark arrestor on exhaust. SWL shall be marked on the drilling mast and on the single joint lifting winch. All hoses and connections shall be pressure rated, safely routed and secured. An adequate and certified portable fire extinguisher shall be provided within the vehicle operator reach. SECURITY CLASSIFICATION: INTERNAL Page 31 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 B.23 WINCHES: B.23.1 GENERAL All winches shall comply with the requirements of the specified standards, the OEM’s operation and maintenance manuals and additionally: All winches shall have a maintenance logbook. The wire rope size shall never exceed the OEM’s recommended size. All winches shall be fitted with safety guard to protect the operator. All winches shall be marked with SWL. All winches shall be fitted with overload limiting device. B.23.2 OPERATIONAL RESTRICTIONS Winch control shall be manned at all times while the winch is in use. B.23.3 WINCHES FOR MAN-RIDING BASKET Winches made for man riding purposes shall be rated to 150kg SWL with load limiter fitted along with slack wire device. In addition to requirements of B.23.1 above, all man-riding winches shall: Be fitted with a wire rope with FOS 10:1. Have a rope spooling device. Have a manual hand brake in addition to an automatic brake system. Be fitted with an emergency stop device. Be constructed so that the brake mechanism is permanently applied at all times when the operating controls are in the neutral position. Be fitted with upper and lower travel limit switches, in addition to an overload protection. Be provided with an emergency manual descent mechanism. Not be fitted with a free fall mechanism Be clearly marked ‘MAN-RIDING’ with SWL. The winch wire rope shall be replaced every six (6) years, irrespective of the condition of the rope. B.23.4 WINCHES FOR MAN-RIDING USING BOSUN CHAIR WITH BODY HARNESS. Man-riding operations using body harness shall only be performed if there is no other reasonably practical and safe means of completing the task. In addition to the requirements of Table 2 of Appendix B the following shall be included: Body harness shall be certified and having the hook attachment in the front of the body. The body harness shall have a minimum SWL of 100 kg and shall have a design FOS of 10:1. Shall be provided with an emergency manual descent mechanism. B.23.5 OPERATIONAL RESTRICTIONS FOR MAN-RIDING WINCHES No simultaneous operation that can interfere with man-riding operation shall be allowed. SECURITY CLASSIFICATION: INTERNAL Page 32 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 The winch used for man-riding, shall not be used for lifting any other item, simultaneously. Effective communications shall be established at all times during the man-riding operations. The communication shall be undertaken by experienced and Competent Persons (LE), familiar with signs, signals, and procedures used in each particular operation. In case of failure of the communication mechanism, the winch operator shall stop the movement of the man-riding and shall resume the operation only after it is safe to do so. Rescue plans must be available. If emergency manual descent mechanism is not available then alternative solution like providing addition standby crane is required. Shall be used only with a certified man-riding basket, or bosun chair, for all personnel lifting operations. Each person riding in the man-riding basket shall have a safety line secured to the hoist hook. B.23.6 FLARE TIP WINCHES In addition to requirements of B.23.1 above, all winches used to lower flare tips are used infrequently and then usually during a plant shutdown. For such situations the wire rope shall be removed from the winch and preserved in a relaxed coiled condition and the winch preserved for long term storage at the location. Prior to use the winch shall be reassembled, inspected and tested at 125% SWL. B.23.7 WINCHES AND DAVITS FOR LIFEBOATS AND RESCUE BOATS All winches and Davits for Life Boats and Rescue Boats shall be checked in accordance with the following criteria: The winch speed shall be verified against the OEM’s recommended limits while lowering the lifeboat with the SWL. The winch wire rope shall be replaced every five (5) years. Winch limit switch shall be checked during inspection, Functioning of winch brake system shall be checked and its condition to be highlighted on the certificate. Lifeboat davit structure shall be inspected for any deformation or propagation of cracks in the metal. NDT shall be performed before and after conducting the PLT. Maximum number of persons permitted in Lifeboats and Rescue Boats shall be clearly marked in addition to SWL. B.24 RUNNING WIRE ROPE FOR LIFTING APPLIANCES: B.24.1 LIFTING APPLIANCE WIRE ROPE INSPECTION AND RETIREMENT POLICY A lifting appliance generally has no ‘redundancy’ so a single failure is enough to cause a major accident. QP’s lifting appliance wire rope inspection and retirement policy has been established based upon current recommended practice, from informed sources such as ISO 4309 and other regulatory bodies. SECURITY CLASSIFICATION: INTERNAL Page 33 of 51 QP STANDARD FOR LIFTING EQUIPMENT AND OPERATIONS DOC. NO. QP-PAI-STD-005 REV.00 A permissible service life of wire ropes is 6 years, from the date of installation and put into service and shall be indicated in the issued certificate of the lifting equipment. For extension beyond six (6) years of services, Electromagnetic (EM) Inspection as a recommended practice to be utilized to detect internal condition of wire rope & report shall be presented to the inspector/surveyor on annual basis before inspection/certification as an evidence of the conducted EM inspection. In addition to EM, bi annual thorough examination & SWL test shall be carried out for a finally concluded integrity/condition assessment of wire rope If any of the above requirements cannot be met then the wire rope shall be retired at a certain prescribed interval. This interval is six (6) years. B.24.2 RETIREMENT-FOR-CAUSE APPROACH: A Retirement-for-Cause approach requires that the wire rope must be retired when the deterioration exceeds certain limits as defined in ISO 4309. Appendix D. Wire rope deteriorates gradually throughout its entire service life. To keep abreast of deterioration, wire rope shall be periodically inspected. The purpose of wire rope inspections is to monitor the normal process of deterioration so that the wire rope can be retired before it is being at risk. There are two major non-destructive inspection methods for the detection and evaluation of wire rope degradation: Visual inspections and Electromagnetic inspections as detailed in QP Corporate Procedure for Lifting Equipment Doc. No. QP-PAI-PRC-004. In addition to the statutory thorough examinations by a QP Approved Inspection Service Provider, the lifting appliance operator is responsible to complete regular in- service visual inspections, before each shift and before lifting a load, in accordance with the lifting appliance OEM’s recommendation, to identify any faults and damage that might arise. If any are found, they should be referred to a QP Competent Pers
