LIFTING HAZARDS and

CRANE SAFE
OPERATION

Prepared by HSE Eng. (ZC & ZKF)

 Introduction

One of the most hazardous operations in

the industry in general is
lifting operations.
lifting operations.
 HSE Golden Rules
HSE Golden Rules

ADMA HSE policy reflects the company commitment regarding Health of Personnel, Safety of
Personnel and Facilities, and Protection of Environment.

Everyone who works for or on behalf of ADMA is responsible for their safety and the safety of
those around them.

The following safety rules will be strictly enforced to ensure the safety of our people and our
communities.

ZKAUs management and Team leader and front line supervisors are accountable for
communicating, training, implementing, and auditing these rules to assure compliance and
performance.

Although embedded in each of these rules, it is important to emphasize that:

Work will not be conducted without a pre-job risk assessment and a safety discussion
appropriate for the level of risk.
All persons will be trained and competent in the work they conduct.

Personal protection equipment will be worn as per risk assessment and minimum site
requirements.
Emergency response plans, developed from a review of potential emergency scenarios, will
be in place before commencement of work.
Everyone has an obligation to stop unsafe work
 HSE Golden Rules of Lifting Operations
Lifts utilizing cranes, hoists, or other mechanical lifting devices shall not
commence unless:

An assessment of the lift has been completed and the lift method and
equipment has been determined by a competent person(s)

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

Rigging of the load is carried out by a competent person(s)

Lifting devices and equipment has been certified for use within the last 12
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(s)
Are you trained and competent to perform this work?
You have an obligation to stop the work if its unsafe.
 Lifting Facts and
Testing Guide

Equipment
Environment
Lifting team
Third parties
 SUMMARY
Lifting operations are hazardous
There have been 7 fatalities associated with lifting within
E&P in year 2001 & 2002
Cranes, winches, hoists, derricks all devices have been
involved
Drilling, wells, production, seismic, construction all
operations have been involved
Roustabouts, floor hands, mechanics, riggers, banksman
,truck drivers all have died
Lifts occur every day but no lift is routine!
Unsafe lifts can be fatal! It can happen to you!
 Stories of past failures
Azerbaijan - 2 floor hands struck by pipe whipping across
rig floor
Egypt - Mechanic dragged off roof when winch failed
Argentina - Truck driver crushed when load shifted in
transfer from winch truck to trailer
North Sea - Banksman crushed when load
slipped during stacking operation
Trinidad - Worker struck by moving load on
boat
Norway - Worker crushed when stacked
tank fell
 Historical reasons for failures
Supervisors treated lifts as routine operations and did
not
audit the equipment, environment or people
People were not competent to do their job
People used wrong lift equipment out of convenience
People overestimated the integrity of lift equipment
People did not maintain lifting equipment
People underestimated the potential for injury of a
suspended load
People did not talk to each other
People did not recognize changing conditions or
improvised rather
than stopped the job
People violated procedures to get the lift done
People repeated unsafe behavior because they got
away with it in
the past
 Agenda for testing a lifting operation
Verify that there is a single point
accountability for the lift operation.
Ask who is involved in the lift.
Test all persons involved on their roles and
responsibilities?
Ask to see the lift plan.
Verify that the lift plan has been approved by
a competent person and test that persons
competency.
Confirm that the lifting device is capable of
lifting the size and weight of the load.
Verify that all persons involved in the lift
participated in the design of the lift.
Request documentation that the lift
equipment has been
certified in the last 12 months.
 Agenda for testing a lifting operation
Ask to see the lift hazard assessment.
Verify that those involved in the lift participated
in the
hazard assessment and test peoples knowledge
of the
hazards and their tolerance level to these
hazards.
Confirm that the hazards associated with the
equipment,
environment, lift team and third parties have
been
identified and mitigated.
Ask to see the lift procedures and confirm that
Agenda for testing a lifting operation
Verify that an inspection of all equipment
has been
completed.
Test the Lifting Device Operators
competencies.
Test the Rigger/Loader/Drill Crew
competency.
Test the Banksman/Signalmans
competency.
Verify that a communication methodology
is in place
and understood by all involved in the lift.
 What did your testing reveal?

Did the lift plan identify all the hazards

associated with
the equipment, the environment, the lift
team and 3rd
parties?
Are you confident that all hazards have been
mitigated?
Are you confident with the competency of
the lift plan
and the lift team?
If not, Stop the Job!
Discuss your concerns and agree to a safer
plan
Document your observations / inspections
 What do you know about overhead crane safety?

Overhead crane safety may not be relevant to all staff

but dont you think it would be interesting to learn how
equipment can be dangerous and harmful, if not
operated carefully.

Overhead cranes are found indoors to help move

objects across the room, warehouse or vertically to a
certain height. This might sound simple and you
probably think that anyone can operate an overhead
crane. But there is a lot more to it.
 Who is responsible?
Crane operators job is very important. The operator should be well
trained, because he is responsible for any unsafe acts or accidents that
might occur at the workplace.

An experienced operator, like myself:

is capable of reducing the movements
required in transferring a huge load.
ensures that the crane is properly
lubricated and maintained.
will not exceed the cranes limitations.
can easily identity the hazards and avoid
any risks associated during operations.
follows procedures and uses a safety
checklist before operations.

What kind of accidents could take place? crane accidents are

commonly due to incorrect slinging procedures and unsafe lifting
attachments.
 Personnel In Charge of Lifting Operations Responsibility
Personnel in charge of lifting operations are responsible for ensuring:
the immediate safety of all personnel involved in the lifting
activity
that all equipment used is suitable for the task and is within test
date
that the lifting operation has been risk assessed and planned
that the activity is executed in accordance with the plan
that lifting operations are halted if an unsafe situation occurs.
Contractors Responsibility
Contractors providing lifting services, shall comply with the relevant
sections of Company procedure, according to their contractual
 Personnel Involved in Lifting
Operations
Banksman
Crane Driver/Operator
Riggers and Slingers

All these personnel should be

properly trained, competent, experienced
and assigned for carrying out control of
lifting operations
 Risk Assessment
The Risk Assessment should account for:
Working under suspended loads
Attaching and detaching the load
Overloading
Overturning
Breakdown in communication during lifting
The environment and location
Proximity hazards
Lifting personnel with non-dedicated equipment
Pre-use checks by the operator
Deterioration in the condition of lifting accessories
The experience, competence and training of personnel
 Planning
Following a Risk Assessment, and the preparation of a
standard instruction or procedure, the person can
normally plan routine lifts on an individual basis.

The degree of planning will vary depending upon the:

Type of lifting equipment
Complexity of the lifting operation
Degree of risk involved.

As a minimum, the plan shall address the risks

identified and should identify all resources, procedures and
responsibilities necessary to ensure a safe operation.
 Before operating crane
....what is the first and most important procedure?

The first and most important procedure is a pre-

operation safety inspection, which checks if the
crane and all working parts operate properly.

A pre-job inspection should be carried out at the

beginning of every shift.

While inspecting the machinery, the operator

should make sure that the area is free from
hazards, materials, equipment and personnel.
 What does the safety inspection include?
Make sure all status lights are working and fused bulbs are replaced
with new ones.
Good housekeeping is required in order to operate a crane. Check if
materials and objects are safely secured and does not obstruct crane
operations.
Make sure that all warning sounds are working and are loud
enough to be heard by all co-workers in the area.
To achieve maximum efficiency, the crane must be lubricated on a
regular basis.
Check the bridge, trolley and hoist. These components should
be able to start and stop smoothly.
Test the hoist limit switch. Remember this should be used during an
emergency and not as a regular means of stopping the hoist.
Closely examine all slings, wire ropes, load blocks and hooks, as
well as other lifting devices that could be worn out or damaged.
Make sure that a fire extinguisher is ready for use.
 The 7 points of Lifting
Know the weight of the load and Never
Guess the weight of the load
Choose the correct lifting tackle S.W.L etc.
Attach the rigging tackle to the load using
the correct hitch
Lift the load 12 from the ground and
check C of G.
Prepare the landing site
Remove the lifting tackle
Check and store the lifting tackle
 General safety rules
Do not attempt to lift loads beyond the specified capacity.
Do not lift loads from an angle. Make sure the cable and hook is straight
before lifting the load. Centre the load before hoisting, to avoid swinging motion.
Do not operate the crane if the switches dont work and the cables
are slightly defected.
Follow signals from trained personnel, except when you are requested
to stop operations.
Make sure that nothing obstructs the movement of the load.
Ensure that nothing links or catches on the load while lifting.
Always place the load onto the ground before elevation.
Do not pass the load over workers.
Do not leave suspended loads unattended.
Do not reverse the motor until movement has been stopped completely.
Reversing a motor during movements is only permitted in an emergency or to avoid
an accident.
 Advice
As we know lifting 1 ton or a 1000 tons is basically the same.
No chances or guess work are taken
If you are in doubt. ASK!
There is no second chance, never mind how high you scream,
once that load has detached itself from the rigging there is only
one place it is going to stop and that is the ground.
If any piece of lifting gear has got a locking device or a split pin
then they must be used.
Know your hitches when slinging pipes. ( double wrap choker
hitch )
Make sure all personnel are safe when a lift is going ahead
Make sure all persons concerned with the lift are trained.
Every lift you do, must be vertical. Side loading is very
dangerous.
 Final Note

Never mind what type of lifting one does that

person must be trained on that particular type
of lifting.
Refresher courses must be taken yearly as
new techniques and legislation comes on the
market.

Lift Safely
Live Another Day.
Any Questions?