WOC HSE Standards Manual

Transcription

1 S1 n,.,., :4 n, _ 4 +. ' A A,4 OIL CO WOC LP & EP Department WOC DOCUMENT NO: WOC-HSE-ST-0001 Section L002 - Lifting Gear Certification REV ISSUE PREPARED BY REVIEWED Y APPROVED BY ISSUE DATE ( 1- D Id& WOC Executive 0 Issued for Use W. McIntosh LP & EP Manager Vice President June 2009 Operations

2 -y Mitt 4'4 on. coo Lifting Gear Certification WOC-HSE-ST June of 11 PURPOSE To ensure that all lifting equipment shall be maintained in good condition for safe use. To ensure safe operations, all lifting equipment will be regularly inspected, certified and/or tested. It is the responsibility of the user to visually inspect lifting equipment each time that it is used, to verify that there are no obvious defects in the equipment. APPLICATION All lifting equipment used by company, contractors and sub contractors POTENTIAL HAZARDS Failure of lifting equipment under load causing serious injury to people and loss/damage to process or equipment. PREPARATIONS A register of lifting equipment test certificates must be provided, updated and maintained. 5. DEFINITIONS Lifting Equipment is equipment that may be attached to and below the crane hooks or equipment which by design is to support a lifted load, such as slings, shackles, cargo baskets, etc. Certification - An assurance by the manufacturer or by a qualified third party inspector that the lifting equipment is safe for use. Load Test - Physically loading a piece of equipment to a predetermined load to ensure that the equipment is capable of regularly lifting at the Safe Working Load (SWL) Limit. Testing shall be performed by a qualified third party. Rated Load the maximum allowable working load established by the sling manufacturer. (When using a multiple branch sling, the rating shown for the single branch sling shall not be exceeded in any branch of the multiple branch sling) Safe Working Limit (SWL) one-fifth of the breaking load.

3 - '''4 0 I L ;CAI - - Lifting Gear Certification WOC-HSE-ST June of 11 Inspection - Examination of lifting equipment to ensure that it is safe for use. The inspection should also ensure that the correct lifting equipment is used. The inspection should be done by an individual who is familiar with the equipment and the work to be performed. Qualified Inspector- A person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work. Contractor Equipment Contractor lifting equipment on WAHA offshore and onshore facilities shall comply with the intent of this standard. The contractor must use this standard or some other appropriate procedure that ensures compliance with this standard. Proof of certification and ongoing re-certification must be produced upon demand. Alloy steel chain slings - chain slings used for overhead lifting. Wire rope slings- slings made of wire rope Metal Mesh Slings - slings requiring special end fittings Natural and Synthetic Fiber Rope Sling - slings made from conventional three-strand construction fiber rope. Synthetic Webbing slings - slings fabricated by sewing woven synthetic webbing of nylon or polyester type yarns, for the purpose of hoisting, lifting, and general material handling. 6. LIFTING EQUIPMENT Lifting equipment is divided into three categories: Category I Category II Category III Slings Miscellaneous Hardware Special Appliances and Fixtures 6.1. Category I Slings This category generally includes slings, which are subject to a high degree of wear and tear resulting from regular use. Category I includes: Wire rope slings (including those attached to cargo containers, etc). Alloy Steel Chain slings Metal Mesh Slings

4 404 AlAtt- ''.4 0; C g'i Lifting Gear Certification WOC-HSE-ST June of 11 Natural and Synthetic Fiber Rope Slings Synthetic webbing slings Cargo nets Personnel baskets (include due to critical nature of equipment) Passenger and service lifts Chain blocks Come-alongs Polypropylene or nylon polyester belt slings are the only acceptable alternatives to wire rope or chain slings and shall be constructed using either of the following strops: Straight strop with a soft-bracketed eye at each end Straight strop with D-rings at each end Inspection and Certification All category I lifting equipment shall have an initial load test (certification) before being placed in service. A record of one time certification shall be kept on site. Thereafter, Category I equipment is to be inspected by the user prior to use to ensure it is in good condition, is rated for the intended lift, and is appropriate for the intended use If the inspection reveals any defect, the equipment shall be withdrawn from service and either destroyed or load tested to ensure that it is capable of lifting at the safe Working Load (SWL) as originally certified. In order to readily recognize category I equipment that has been certified, within any 6 months period, a color code system shall be used, as outlined in Identification and Records Personnel using slings must ensure that the slings are free of defect such as frayed or broken strands or straps, un-stranding, bird-caging, core protrusion, damage caused by corrosion, chemical attack, crushing, kinking, abrasion or stretching.

5 .4,:vp, vo, ''l OIL C0 Lifting Gear Certification WOC-HSE-ST June of Each check must be 100 percent acceptable. If not, the category I item must be removed from the service and destroyed. Personnel responsible for destroying it should ensure to discard the destroyed sling's certificate A semi-annual inspection by qualified third party inspector shall be performed on wire rope slings with the following inspection tools to determine the condition of the wire rope (but not limited to): steel tape sheave groove gauges for worn sheaves used in accordance with API RP 9B, latest edition Quality calipers and/or micrometers with at least 1/1,000 th of an inch accuracy Chalk or tape measure (wire rope tester) This semi annual inspection is to be performed in line with the Identification and Records Whenever category I lifting equipment is used, it is the responsibility of the user to ensure that it has the appropriate color code. Any equipment which has an out of date color code is to be removed from service until inspected, (rectified: deleted) and properly color coded No hand made slings are allowed for lifting equipment. Personnel baskets shall be marked with the maximum capacity in number of persons and maximum weight Category II - Miscellaneous Hardware This category generally includes lifting hardware or tools that are purchased from a bonafide manufacturer and by design are capable of making safe lifts to the Safe Working Load. Category II hardware includes:

6 ii,gblv -..--,,- 4 oti c Lifting Gear Certification WOC-HSE-ST June of 11 Pulleys (pulley blocks, snatch blocks, sheaves) Eye bolts Hooks Come alongs Plate clamps (including attached slings) Air Tuggers Cargo containers Shackles Barrel hooks Other similar hardware Wire rope slings (including those attached to cargo containers, etc) Chain slings All category II hardware is to be routinely inspected by the user to ensure it is in good condition (i.e. Not bent, cracked, rusted, damaged, etc.), is rated for the intended lift, and is appropriate for the intended use. If the user suspects that a defect exists which may affect the safety of the equipment, it should be removed from service, and be immediately repaired or destroyed Category II hardware does not require color coding If the user suspect that a defect exists which may affect the safety of the equipment, it should be removed from service and be immediately destroyed Category Ill - Special Appliances and Fixtures This category generally includes all lifting appliances which are intended for a very specific use and which are, by design, limited to a particular lift or lifted load. Category III appliances and fixtures include: Cargo baskets Hoist runway beams

7 _ Viik..94 or v 4 k * Lifting Gear Certification WOC-HSE-ST June of 11 Special - lifting tools, support, and stands Spreader bars (frames) Cylinder Racks Barrel racks Transportable tanks Category Ill appliances are designed to support a specific load or load limit. Category Ill lifting appliances should be marked, stamped, or stenciled to indicate the maximum load capacity or the specific use Runway beams shall be marked with the maximum support capacity. The hoist installed will be a category II item and will be marked with its maximum capacity Any equipment supplied by a manufacturer for a specific lift (engine/ compressor tools, spreader bars) shall be used only for the specific intended purpose If a lifting appliance is built by or for WAHA for a specific purpose, the appliance shall be properly engineered and include drawings and calculations to ensure the capacity of the load supporting elements (i.e. lifting eyes, attachments). After fabrication, the appliance shall be proof tested by a competent person who shall produce a written test certificate Special tool kits, such as Rolls Royce /solar overhaul kit, will likely contain lifting equipment from all three categories. All equipment within these kits shall comply with the policy relevant to their category Platform cranes, including cables, block, pendant and hook, are not included within this policy as they are currently covered by an annual certification inspection program which includes testing when necessary.

8 4-i aft&, Itii'ai lfy.94 0,-Lc Lifting Gear Certification WOC-HSE-ST June of IDENTIFICATION AND RECORDS 7.1. Category I Equipment shall be identified with a unique identification clearly marked on the equipment that includes: Serial number (#1, #2, #3, etc.) Safe Working Load (2.5 ST etc. All weights shall be marked in short tons on Category I equipment). Third party company that performed the test The identification shall be stamped into the body of the equipment. When this is impractical, the equipment may be identified with a fixed tag Category I equipment shall be color coded to indicate compliance with semi annual inspection or re-certification. The color code will be affixed or painted onto the lifting equipment. The periods for color code compliance will last for six month. The following four colors, blue, orange, green and yellow will be used in rotation. The rotation of the color will be communicated before the end of six-month period An inventory record of all category I equipment shall be maintained at point of use the inventory should consist of identification number, type, quantity and serial number, the original test certificate and date of last re-certification, date of purchase Category II Equipment (Miscellaneous Hardware) shall be marked with the manufacturer's rated SWL limit in clearly visible and understood terms (i.e.2.5 ST) with an attached tag and permanently marked onto the hardware Category II hardware does not require biannual inspection/registration unless the user suspects a defect which may affect the safety of the equipment. Therefore, Category II hardware does not require color coding Category III Equipment (special Appliances and Fixtures) shall be marked with the SWL capacity or the specific purpose. Special lifting tools may be contained within a specifically

9 -I3-t *,, 0,i c.= M Lifting Gear Certification WOC-HSE-ST June of 11 marked and dedicated kit. In the case of special tool kits which contain Category I hardware (slings), such equipment is subject to the requirements of Category I, and shall be identified, certified, color coded and recorded in accordance with the policy for all other Category equipment. 8. FAILED EQUIPMENT 8.1. Any equipment which appears to be defective as a result of routine inspection by the user shall be withdrawn from service and either junked or destroyed. Do not attempt to repair lifting equipment, except Category III lifting equipment repaired and re-certified by a third party competent person Any equipment that physically fails (breaks) shall be subject to a written failure report. The specific intent of a failure report is to determine if changes are required to the lifting gear inspection procedures. Analysis and testing of a failed component may also be appropriate.

10 - _ - c, y4, -,.., c Lifting Gear Certification WOC-HSE-ST June of 11 TEST LOAD TABLE All new purchased slings shall be certified and tested by the manufacturer to meet the requirements of the test load table. This should be done as part of the certification process. Category I (Slings) Cargo nets Personnel baskets Test Load Category II (Miscellaneous Hardware) Wire rope slings Chain slings Nylon polyester Cargo containers Barrel hooks Category II (Miscellaneous Hardware) Plate clamps Shackles Pulleys Come-along Eye bolts Single sheave block Multi sheave block less than 20 tons Multi sheave block tons Multi sheave block above 40 tons Hooks less than 50 tons Hooks tons Hooks above 100 tons 4 x SWL SWL + 20 ton 1-1/ SWL + 50 ton 1-1/.

11 4 It '',, 01, c Q Lifting Gear Certification WOC-HSE-ST June of 11 REPAIR OR ALTERATION Any item of lifting equipment of category Ill which has been repaired or altered in any way from its original configuration should be load tested and certified according to this procedure before it is used. CONTRACTOR EQUIPMENT Contractor lifting equipment used on WAHA offshore and onshore facilities shall comply with the intent of this standard. The contractor must use this standard or some other appropriate procedure that ensures compliance with this policy. This will be mutually agreed by WAHA and the contractor (bridging document). Policy compliance shall be communicated in pre-tender information. Proof of certification and ongoing re-certification will be produced upon demand. 11. REFERENCES: ASME B " Slings" API RP 9B, " Application, Care, and Use of Wire Rope for Oil-Field Service API RP 2D," Recommended Practice for Operation and Maintenance for Offshore Cranes"