Freeport Site Standard

Transcription

1 Environmental, Health and No.: BCF Page: 1 of 15 REVISION HISTORY Date Revision Details of Change Number 11/14 4 formatting, grammar, and punctuation edits alphabetized the featured words in the Definitions section, which changed the numbering on each word 2.4 change to critical lift definition: When the crane load exceeds 75% of the load chart 2.4 added to the definition of a critical lift: Chemicals OSBL that the XA Asset Manager deems critical to lift over 2.15 Definitions: rig mats: added timber 2.13 Definitions added the definition for a qualified person - a person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project. 2.3 Definitions added the definition for a competent person - one who is capable of identifying existing and predictable hazards in the surroundings or work conditions which are unsanitary, hazardous or dangerous to employees and who has authorization to take prompt corrective measures to eliminate them changed wording to clarify: If nylon chokers are used on anything with a sharp edge, softeners shall be used General Requirements: Added proximity to roadside ditches should be considered during planning added weight of object to be lifted shall come from one of the approved sources and descriptions of the approved sources.

2 Environmental, Health and No.: BCF Page: 2 of 15 REVISION HISTORY Date Revision Details of Change Number 11/ Matting and Outrigger Pad Requirements: Changes made to the mat matrix Matting and Outrigger Pad requirements: Added weight needs to be distributed across the entire mat to maximize the surface area of the mat for effective load distribution Matting and Outrigger Pad requirements: added Construction Site Services Manager to the approval list for matting variances when lifts are not weight critical. 6.0 Related Documents Added Attachment 5 OSBL Critical Lift Area Map

3 Environmental, Health and No.: BCF Page: 3 of PURPOSE to establish the minimum requirements that must be accomplished for rigging, hoisting, and lifting loads on the Freeport site 2. DEFINITIONS 2.1 All Other Lifts those lifts that are neither prohibited lifts nor critical lifts but still apply under this standard 2.2 BASF Lift Evaluation Plan (BLEP) an analysis of all lifts that takes into account the manual rigging, the crane, the swing, the load weight, rigging plans, etc., and equipment that will be used for the lift 2.3 Competent Person one who is capable of identifying existing and predictable hazards in the surroundings or work conditions that which are unsanitary, hazardous, or dangerous to employees and who has authorization to take prompt corrective measures to eliminate them 2.4 Critical Lift any lift over overhead energized transmission power lines (Power lines in cable trays are excluded.) when the crane load exceeds 75% of the load chart when lifting requires two (2) cranes Soil or ground conditions are not designated as stable on the stable soil map (Attachment 4). Use of a rig hoisted personnel platform is required. chemicals ISBL that the Production Execution Manager deems as critical to lift over chemicals OSBL that the XA Manager deems Critical to lift over (See Attachment 5 OSBL Critical Lift Area Map.) Note 1 For the intent of this standard, rig hoisted personnel platforms are identified as Critical Lifts. The form attached with BCF , Rig Hoisted Personnel Platforms, will be required in addition to a Critical Lift form. Note 2 The Production Execution Manager may exceed the requirements of this standard and classify additional lifts in his/her process area(s) (ISBL) as Critical Lifts. Where exercised, these additional critical lifts shall be documented in the control room. 2.5 Flag Person For the purpose of this standard, this is the person who is giving the hand signals and/or radio communication to the crane operator relating to the direction and speed of the object being lifted.

4 Environmental, Health and No.: BCF Page: 4 of Lifting Attachment an engineered component (lifting lug, trunnions, threaded lifting eye, etc.) attached to the equipment or component designed to handle the required load during any lift or moving operation 2.7 Manual Lift a lift made with a chainfall, come-along, etc., that does not involve a mobile crane or overhead crane or winch; Hand lining a bucket of tools up a scaffold or other elevated work surface is not considered a lift. 2.8 Mobile Crane a wheel mounted or crawler tread crane consisting of a rotating superstructure, operating machinery, an operator s station and boom mounted on a base or platform; Its function is to lift, lower, and swing loads at various radii. This is to include multiple and single control station cranes. 2.9 Overhead Energized Transmission Power Lines 2.10 Permit Issuer Signature For the purpose of this standard, the Permit Issuer Signature means that the Permit Issuer is stating that he/she has verified that the BLEP has been completed and all required signatures have been obtained Prohibited Lift any lift over personnel or an occupied portion of a building any lift in which the load exceeds 100% of the load chart of the crane any part of the cranes or loads within ten (10) feet of 50kV 2.12 Project Owner For the purpose of this standard, the signature on the Critical Lift Check sheet(s) for a Project Owner is intended to be the Project Manager or Construction Engineer responsible for the work where a lift is performed. If this is not a capital project, the Area Maintenance Manager may fill this role Qualified Person a person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project 2.14 Qualified Rigger a person who has successfully completed both the written and field performance assessments for the course entitled Rigging Fundamentals available from the National

5 Environmental, Health and No.: BCF Page: 5 of 15 Center for Construction Education and Research, NCCER or an equivalent recognized training (Rigging Fundamentals and Advanced Rigging are the two qualifications.) 2.15 Rig Mat plywood, timber, or steel construction used under the crane s outriggers to support the crane; See sizes and construction in Section 4.2 Matting and Outrigger Pad Requirements 2.16 Rigging the act of attaching a lifting device (manual or mechanical) to an object to be lifted using the appropriate lifting hardware such as slings, shackles, etc., that are rated for the load 2.17 Stand-By Person For the purpose of this standard, a stand-by person is a designated person who is positioned at the swing radius of a lift to warn others of the overhead hazards when barricades are not used. This can also be the drum watch when the Anti-Two Blocking system is required to be compromised Uninterrupted Radio Communication an intrinsically safe, dedicated radio and or channel for the crane operator and the flag person that no other workers or work crews have that can be walked on during the lift 2.19 Overhead Energized Transmission Power Lines for the purpose of this standard, Overhead Energized Transmission Power Lines are electric power transmission lines suspended by towers or poles. 3. SCOPE This procedure applies to all manual lifting, mobile lifts, bridge mounted cranes, beam mounted chain hoists and lifts using/rigged from process piping or supports made on the BASF Freeport Plant Site. Exceptions are specific in nature and not intended to be exempted from all of the rigging and lifting general requirements. Specific exemptions include: 1. Lifts in shops are excluded from needing a BLEP and rigger qualifications. 2. Manual lifts are also excluded from needing a BLEP. However, rigger qualification requirements still apply. 3. When using a permanently installed, overhead crane or winch lift and rigging is not required, (the crane/hoist hook is attached to the lifting eye or lug) the BLEP is not required, and a qualified rigger is not required.

6 Environmental, Health and No.: BCF Page: 6 of When permanently installed overhead cranes are used for routine tasks that require rigging (e.g., changing filters, lifting screens) and a written procedure, or a Unit Specific Lift Checksheet exists for the bridge mounted cranes being used, the BLEP is not required, and a qualified rigger is not required. 4. PROCEDURE 4.1. General Requirements Prohibited lifts shall not be made at any time Lifts made with cranes cannot be performed in the presence of lightning. The maximum allowable wind speed shall be either 20 mph, the maximum wind rating of the rig boom, or the calculated maximum allowable wind load on the object lifted, whichever is less All lifts shall be in accordance with BCF Chain Hoist and Rigging Equipment Use and Inspection All lifts (other than those listed as exceptions under Section 3 of BCF Rigging, Hoisting, and Lifting Requirements) will require a pre-lift evaluation using the BASF Lift Evaluation Plan (BLEP) located in Section 6 - Related Documents. This form is a progressive plan that is to be completed according to the lift type. A. For permanently installed overhead cranes (with no written procedure or unit specific lift checksheet) and winch lifts, the first part of the progressive form must be completed. This is to identify what is being lifted, how much it weights, how to connect it, and if the rigging devices capable of supporting the load. B. When mobile cranes are involved, additional portions of the BLEP will be required that will include information about the crane, radius, swing, matting requirements, etc. C. If the lift is a critical lift, the critical lift portion of the BLEP shall be completed by the project owner and posted in the control room Persons who will be assigned the task of rigging for a lift shall be qualified per the definition in Section 2. Exception: A qualified rigger is exempt when a written procedure is in place for routine lifts. The written procedure shall include what is being lifted, how much it

7 Environmental, Health and No.: BCF Page: 7 of 15 weighs, and how to connect onto it. It shall also include the rigging devices capable of supporting the load Areas where lifts are being made shall be barricaded, or a stand-by person shall be stationed in the area to keep unauthorized personnel from entering the lift area A qualified rigger shall accompany all cranes and be the person ultimately responsible for rigging and or supervising the rigging of the lifting activity. Note: Roles do not mean bodies. The intent is that someone is qualified to rig equipment for the lift being made The crane operator is ultimately responsible for the safe lifting of material/equipment All loads must be controlled from swinging. This may be through the use of a tag line or a person hand-steadying the load Loads will not be rigged from forks of forklifts/lulls unless a manufactured lifting device is approved by the manufacturer for the use intended Choker, shackle size, and lashing are to be calculated using the size and weight of the load to be lifted If nylon chokers are used on anything with a sharp edge, softeners shall be used All chokers must be inspected before each use and at least daily as required by CFR Slings Anti-two block should not be overridden. For the exception, the lift shall be stopped until a dedicated person is assigned to monitor the two blocking system It is recommended that the original vendor drawing be reviewed to see if a spreader beam is required for lifting before any lift attempt To ensure proper lifting safety, the crane operator and rigger must be familiar with the design limitations of the lifting attachment. It is not the purpose of this procedure to provide the rules and recommendations to address the lifting problems that may be encountered Cranes used on the Freeport site are required to have hydraulic power up and power down hoisting drums. Hoisting drum brakes are required to be hydraulically released.

8 Environmental, Health and No.: BCF Page: 8 of 15 Friction cranes must have BASF Construction Management approval before being used on the unit Carry deck cranes are not permitted on uneven or unstable soil unless matted When a lift is to be made using a fixed lifting attachment on an existing piece of equipment, the lift will not be permitted until the lifting attachments have been inspected to certify integrity to the lifting attachment. At minimum, this inspection shall be a visual inspection looking for cracks, nicks, wear, and deformation of the attachment. For critical lifts, welded attachment inspections will be conducted by Mechanical Services Group (MSG). On critical lifts, additional Penetrant Testing/Material Thickness inspection is required After the visual inspection, if required, any or all of the inspection methods below could be applicable to ensure the integrity of the lifting attachment A thickness check of the lifting attachment, the doubler and the adjacent vessel surface may be conducted A dye-penetrant inspection or a wet fluorescent magnetic particle inspection of the welds may be conducted Lifting off a nozzle shall require an engineered assessment by the MSG who will issue a report and file the results in the equipment file A copy of the BLEP is to accompany the SWP in the field Proximity to ditches should be considered during planning to insure the stability of the crane setup area Weight of object to be lifted shall come from one of the following sources: documented e.g., job books, equipment details stenciled e.g., stamped on iron then calculated, weight on equipment name plates calculated from a known source e.g., pipefitters blue book calculated by a qualified person 4.2. Matting and Outrigger Pad Requirements When possible, to avoid tipping, all outriggers must be fully extended.

9 Environmental, Health and No.: BCF Page: 9 of A good footing MUST be assured before lifting any load The following matrix identifies the surface area, the crane tonnage, and the mat dimensions. Mat use is restricted to the following matrix Landscape timbers, pallets, loose railroad timbers, or any other cribbing that is not permanently joined for stability may be used All mats 36 x36 and smaller, must be at least 3-ply, ¾ laminated plywood construction- with some means of handling designed in rope handles, hand holes, round design, etc Crane weight needs to be distributed across the entire mat to maximize the surface area of the mat for effective load distribution Make sure the crane is level. When building a pad, a minimum of compacted crushed limestone rock must be used to level and stabilize the supporting sub-surface. MAT MATRIX 55 Tons and Under Tons Over 100 Tons 1. Work on 6 concrete or main plant roadways. Use 30 x30 mats or 30 diameter. Use 3 x3 mats or 36 minimum 4 x8 mats diameter. 2. Work on fixed, Use 30 x30 mats or 30 minimal 4 x8 mats minimum 4 x8 mats stabilized ground. 3. Work on any other surface than the above. diameter. Use 4 x8 or 8 x16 mats or mat dimension calculation protocol. Use 4 x8 or 8 x16 mats or mat dimension calculation protocol. minimum 8 x16 or mat dimension calculation protocol Mat dimension calculation protocol: Perform a compaction test on the area where the crane is to be set. Use the compaction test report to determine the mat dimensions. If a compaction report is not available, use 500 PSF soil bearing load to determine the mat dimensions. Note: Ten (10) ton or fewer capacity cranes are not required to use mats unless the bearing surface is soft and unstable Attachment 4, the stable soil map, will identify non-concrete areas on the Freeport site that have been determined to be stabilized White rock does not constitute stabilized ground.

10 Environmental, Health and No.: BCF Page: 10 of When in doubt, consult the Civil Design group Check the condition of the outriggers frequently for settling. If settling is observed, stop the lifting and reevaluate the soil conditions and determine additional matting requirements necessary to eliminate settling Variances to the matting requirements as defined by the matrix can be authorized by the Sr. Production Manager/Director, Site Utilities/Infrastructure Asset Manager, Power Distribution Manager, Site & Area Logistics Manager, or Construction Site Services Manager when the lifts are not weight critical. An example would be if a 100- ton rig is required to lift relief valves because of the reach, but the location is not concrete or stabilized. Timber matting would not necessarily be required if the soil conditions can support the rig with standard outrigger pads. In this case, a variance could be solicited. Confirmation by TES Civil may be required to validate this request Bridge Mounted Cranes and Beam Mounted Chain Hoists For the most part, bridge mounted cranes or permanently installed beam mounted hoists have been installed in the units for specific activities. The cranes/hoists have been sized to the equipment intended to be lifted and usually require little or no rigging when used Permanently installed beam mounted chain hoists are considered to be manual lifts and do not require a BLEP When bridge mounted cranes are used for routine tasks that require rigging, (e.g., changing filters, lifting screens), and a written procedure exists, and/or a unit-specific lift checksheet exists, the BLEP is not required. A qualified rigger is also exempt when a written procedure is in place for the lift. The written procedure should include what is being lifted, how much it weights, and how to connect to it. Also include the rigging devices capable of supporting the load When the lift is not routine and requires rigging from the bridge mounted crane, the BLEP will be required, and the riggers must be qualified riggers When rigging is not required, (the crane/hoist hook is attached to the lifting eye or lug) the BLEP is not required, and a qualified rigger is not required.

11 Environmental, Health and No.: BCF Page: 11 of Permits, Check Sheets, and Forms Permits, Check Sheets, and Forms If the crane is traveling and or setting up in an electrically classified area, the hot work and vehicle entry boxes on the SWP shall be checked to authorize the crane in the electrically classified area Safe Work Permit (SWP) When a crane or manual lift is required for work tasks, the Rigging/Lifting box on the SWP shall be checked to authorize the lifting task. For manual lifts, it is not a requirement to complete and attach a BLEP to the SWP A question in the work environment section of the SWP must be addressed with the permit acceptor to ensure that lifting plans are in place before lifting and to ensure that qualified riggers are used when rigging is required BASF Lift Evaluation Plan (BLEP) A BLEP shall be completed by the lifting crew members. If a crane is involved, the crane operator will sign and verify the BLEP. The qualified rigger, flag person, and foreman shall sign the BLEP before rigging and lifting activities A BLEP shall be completed for the heaviest and/or most difficult lift. Example: Cranes are often used for multiple lifts without repositioning. In the case of lifting scaffold materials, a compressor, or a reactor, etc. The rigging and materials will be significantly different for each lift; therefore, a BLEP shall be created for the most critical lift and list the associated lifts in the evaluation plan If the crane moves, a new BLEP will be required to ensure that boom swing, length, load weights, etc. are considered and documented. Note: 1. If a ground marking is used for the tires and outriggers, the crane may move and return to the marked spot without a new BLEP. 2. For repetitive crane movement activities, a single BLEP may be used provided the conditions are evaluated at each setup location for the crane (e.g., soil conditions, crane swings and

12 Environmental, Health and No.: BCF Page: 12 of 15 reach, special conditions related to the location, etc.) and are included in the BLEP The operating owning department will review each BLEP in the field with the person (permit acceptor or work crew member) most knowledgeable about the job to evaluate potential hazards and ensure that the lift can be performed safely. (This action is to complete the 4- Eyes Principal, per BCF , Section 3.23) For planning purposes, a BLEP may be coordinated, planned, and completed in advance of the task, just not signed until the day and time of the lift If a lift goes beyond the shift of the original lift crew, the members of the new lifting crew shall review the BLEP and sign onto the existing BLEP in the vicinity of the original signatures. Note: The revalidation of the SWP for this job task may be affected. Consult SWP requirements for revalidation of the SWP The BLEP may be issued for up to 31 days as long as the BLEP scope does not change The operation s daily inspection is the document of the review for each additional day of the lift For lifts that continue for multiple days, the operation s daily lift Inspection form will be completed each day of the lift and remain in the control room (or designated permit area) with the associated BLEP The original BLEP will be kept in the field and turned in at the completion of the job. One copy of the BLEP will be kept with the associated SWP for the duration of the lift Critical Lifts When a lift is defined as a critical lift, the critical lift portion of the BLEP will be required to be completed If a company completed their own lift plan, attach it with the BLEP.

13 Environmental, Health and No.: BCF Page: 13 of The Production Execution Manager or his designee shall sign the critical lift portion of the BLEP The operating owning department shall provide the crane operator with the weight of the equipment being lifted. Note: Weight calculations must include the weights of add-on appendages, equipment modifications, scale build-up, sludge, liquid, insulation, etc. The weight of the rigging must be added to the equipment weight when calculating loads A critical lift may be issued for multiple days as long as the crane does not reposition (move to another area) and as long as the critical lift s maximum identified weights are not exceeded The operations daily lift Inspection is the document of the review for each additional day of the critical lift The operations daily lift Inspection will be completed each day of the lift and remain in the control room with the associated critical lift checksheet If the crane has to reposition to make additional lifts, the Lift Area Evaluation section of the critical lift form shall be revalidated by the project owner to ensure that the area is acceptable for the crane, and necessary precautions are identified for the future lifts When two (2) cranes are used, attach the company s lift plan to the BLEP Hang/Hoist Loads from Plant Piping Authorization Any rigging or hoisting from piping or structural steel must follow the piping and structural assumptions included in the Authorization to Hang/Hoist Loads from Plant Process Piping form attached to this standard and attached to the SWP. Attachments 3A/B shall be used and attached to the SWP when rigging and hoisting fall outside the assumptions Any lifts exceeding the assumptions of the Authorization to Hang/Hoist Loads from Plant Process Piping form must be evaluated by a Mechanical and/or Civil Engineer and documented using the Authorization to Hang/Hoist Loads from Plant Process Piping form before applying a load.

14 Environmental, Health and No.: BCF Page: 14 of The approval shall be reviewed and approved by the Site Design Manager or his designee and the operating owning department The completed and signed authorization form will be presented to the SWP issuer at the time the SWP is issued for the work requiring rigging from process piping A copy of the authorization form will be made. The original form will be attached to the control room SWP, and a copy will be attached to the field SWP Authorizations to hang/hoist from plant piping or structures may be completed in advance of the work Flag Person Requirements All flag persons must be trained in hand signals and qualified as competent A flag person shall be provided for all mobile crane lifts Communication During a Lift The flag person will communicate with the crane operator with hand signals or radio communication If the flag person is out of the line of sight with the crane operators, an additional flag person may be used; however, one must consider the delay in relaying signals and take additional precautions to prevent delayed communication with the crane operator. 5. TRAINING If radio communication is used because of the loss of visual hand signals, the radio communication shall be uninterrupted The crane operator and the flag person must each have a radio and ensure that it is in working condition Crane operators shall be licensed and certified for the crane sizes and types they are operating Flag persons shall be trained and qualified as competent.

15 Environmental, Health and No.: BCF Page: 15 of Riggers shall be trained and qualified as stated in the definition section of this standard for Qualified Rigger For contracted or rental equipment, it will be the contractor s or crane provider s responsibility to ensure that such training and certification is current and producible upon request For BASF owned and operated equipment, it will be the equipment owner s/unit s responsibility to ensure that such training and certification is current and producible upon request. 6. RELATED DOCUMENTS Attachment 1: BASF Authorization to Hang/Hoist Loads from Plant Process Piping form Attachment 2: BASF Lift Evaluation Plan (BLEP) Attachment 3A: Allowable Hoisting Loads on Piping in Racks Attachment 3B: Allowable Hoisting Loads on Piping in Racks Attachment 4: Stable Soil Map Attachment 5: OSBL Critical Lift Area Map OSHA, CFR 1926 Subpart N Helicopters, Hoists, Elevators, and Conveyors OSHA, CFR Hoisting and Rigging OSHA, CFR Slings