Title: Rigging and Lifting Procedure Issue Date: 09/04/2015 Rev 4

Transcription

1 Environmental, Health and Safety Procedure Title: Rigging and Lifting Procedure Issue Date: 09/04/2015 Rev 4 Procedure No.: Prepared By: Craig Hodgson Approved By: Page: 1 of Purpose The purpose of this procedure is to provide guidance to all employees and contractors engaged in the transportation, rigging and lifting of equipment within the BASF Kankakee Site. This procedure will provide the minimum requirements that must be met when working with rigging and lifts. The intent of the procedure is to ensure the safe execution of all site lifting, loading and unloading, transport and installation/erection processes at the Kankakee Site. 2.0 Scope This procedure applies to all employees and contractors performing rigging and lifting in this facility. The following procedure outlines the steps necessary to complete a lift within the Kankakee Site. All lift activities, preparation and calculations are the responsibility of the lifting contractor. This procedure does not apply to lifts involving permanently mounted lifting beams within the plant facility. The Kankakee Site does not perform evaluation of the data and only reviews the information supplied by the lifting contractor who is responsible for employing the necessary Competent Person(s) to safely perform requested lifts at the facility in line with recommended industrial and engineering practices for the performance of lifting activities. 3.0 Definitions Contractor Contractor Designee Contract Initiator PPE Rigging and Lifting Permit Issuer Critical or Engineered Lifts Any company or person not directly employed by BASF who is performing physical labor at a BASF facility. Included in this category are personnel involved in construction, field engineering and any work involving the repair or installation of BASF equipment. The contractor supervisor or other contract management personnel responsible for training their respective contract employees in the Kankakee Site Specific Training. The person making the request for contractor work and is responsible for the contractor when they are on the Kankakee site. This may or may not be a BASF employee. Personnel Protective Equipment The BASF employee(s) responsible for lifting activities in an area. Only those site personnel who have been qualified and trained to write Rigging and Lifting permits are authorized to do so. A critical or an engineered lift is defined: 1) As any lift in excess of 25 tons (50,000 lbs) 2) As any lift where multiple cranes are utilized in tandem other than in tailing operations. 3) As any lift where the soil conditions may be suspect for Printed copy is uncontrolled

2 Allowable Soil Bearing Pressure Certified Weight Competent Person Crane supporting the lifting equipment. 4) As any lift where the lift occurs within the prescribed clearances as found on Table ) As any lift deemed critical by the EHS Department or Contract Initiator. The maximum bearing pressure that can be placed on the soil spread over a predetermined area with weight distribution methods that are determined adequate and soil area safe by a qualified civil/soils engineer. All calculations for adequacy of soil bearing pressure for the set up of any crane involved in a lift determined to be a critical or engineered lift or the transportation of heavy loads within the plant will be subject to review by the project manager or the manager engineering services Kankakee. The required soil bearing pressure shall be determined by the crane s manufacturers recommendations for minimum support required under outrigger pads or Crawler crane tracks and the any additional load added to this by what the crane(s) may be lifting. If confirmation is required of the soil bearing pressure in any area, this will need to be provided by a soils engineer acceptable to both BASF and the lifting company. Certified weights shall be established by an agreed upon procedure that may include the following: Confirmation of weight using a calibrated and accurate load cell. Confirmation of weight issued by an authorized weighing authority. Vendor drawings which stipulate the weight of the equipment with that weight being factory confirmed by calibrated weighing equipment. Loading weights recorded by the transport vessel cranes, providing they are calibrated and accurate. The weight device utilized shall also have the capability of determining the Center of Gravity (CoG) of the lift. Weight where the lifting equipment (cranes) is to be subject to a load greater than 85% of the lifting equipment stated load rating capacity for a given configuration, boom length, radius shall also be certified as this criteria falls into the design lift category. The actual process agreed upon will be signed off on by the contractor and a BASF Representative. A competent person, as defined in 29CFR (f), is one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. A mechanical device used for the purpose of raising, shifting, or lowering a load.

3 Crane mats Non-Critical Lifts that do not require a Rigging and Lifting permit to be filled out. Non-Critical Lifts requiring a Rigging and Lifting permit to be filled out. Crane mats shall be constructed of composite material, wood, or steel sections, that have known mechanical properties so that bending, shear, and compression stresses can be calculated and compared to allowable stresses. In certain applications, steel plate may also be used to spread loads imposed by lifting equipment. The structural integrity of all crane mats must be proved by engineering calculation for each engineered lift. Lifts under 2500 lbs including rigging and tackle. Lifts not over or not within the minimum required clearance of power lines as defined in Table Lifts not over piping, tanks or equipment containing hazardous chemicals. Lifts between 2500 lbs and 25 tons including rigging and tackle. Lifts over piping, tanks or equipment containing hazardous chemicals. As any lift where the lift occurs over critical operating equipment. Heavy Haul Heavy Rigging Activity Hazardous Area Horizontal Rotations Lifted Weight Live Operating Equipment Load Any transportation operation or activity that requires the use of equipment or machinery of an unusual ability or exceptional capacity above and beyond that of the standard highway tractor/trailer configuration or that would surpass AASHTO HS-20 wheel loading requirements. Any lifting or load handling operation that falls within definitions below: An area that is potentially dangerous to personnel during rigging and lifting activities due to either the possibility of falling objects or the release of energy due to falling or swinging objects, and also where personnel can be trapped or caught in a pinch area by moving equipment. This area should be roped/taped off with Red-Do Not Enter tape. A sign should be attached to the entrance area of the taped off area to provide a listing of authorized entrants to the hazardous area. This is in addition to the requirements set forth in Barricade Protection Program EHS Any lifting or load handling operation with items requiring rotation of objects perpendicular to the attachment point of the load. Requires a documented lifting plan when these activities are part of the job scope. The known or proven, not calculated, weight of the lifted equipment, modules and/or structures including the weights of insulation, piping, ladders & platforms, etc., if applicable. When designing lifts the contractors involved must clearly understand whether the weight they are dealing with is either the lifted, calculated or certified weight to avoid any confusion and /or miscalculations. Operating Process Equipment that if damaged would impact production processes preventing customer shipments or scheduled product production. The item or equipment being transported or to be lifted. In most lifting operations, this term shall include all under-the hook load handling

4 Rigged Weight devices and any other item that must be considered as part of the load for lift capacity calculations. The Lifted weight plus the weight of the load block, hoist cable above the load block (as applicable), auxiliary blocks, fly jib attachments, pendants and all rigging under the hook. 4.0 Responsibilities Person Responsible Responsibility All BASF Be aware of contractors, and sub-contractors within the facility. Employees Report any non-conformances to the Contract Initiator. Be aware of the restrictions for entering the hazardous work area. Stop any contractor violating plant procedures or performing an unsafe act. Record such infractions using site procedures. BASF permit issuer Review jobsite specific hazards with the contractor prior to issuing the Safe Work Permit. Determine the need for an additional Rigging and Lifting permit, subject to the guidelines of this procedure. Verbally review the lifting plan, with the Rigging Supervisor and Lifting Equipment Operator when a lift or rigging operation does not require a Rigging and Lifting Permit. BASF Rigging and Lifting Permit issuer Review jobsite specific hazards with the lifting contractor prior to issuing the Rigging and Lifting Permit. Evaluate the ground conditions, suitability for a lift. Evaluate the clearances around the lift area. Evaluate the need for exclusionary zone for higher hazard lifts. Review the permit for any errors that may be present prior to the issuing of the permit. Check crane operator s credentials, inspections to see if they are current. Authorized Rigging and Lifting permit writers are limited and must be trained annually in this procedure. Review the lifting plan with the Rigging Supervisor and Lifting Equipment Operator. Revalidate the permit if the plan changes, after review of the changes. Contract Initiator Ensure that Crane/lifting contractors are aware of all aspects of this procedure. Provide Contractor Safety Orientation (Attachment ) as needed to any contract employee who does not have proof of General Hazards Training. Participate in the Contractor Safety Discipline Process as required by site policies. Review the data required on the Rigging and Lifting Permit before the lift or rigging is scheduled and ensure that area is safe and no issues require correction or accommodation before the activity. Discuss the need for any inspections of equipment lift points with Mechanical Integrity Engineer or Reliability Engineer before scheduling lift. Contractors Comply with all provisions of procedure. Contact the Contract Initiator or Permit Issuer with any questions regarding this procedure Project Engineering Evaluate Crane/Lifting contract company submittals of prequalification survey and written safety programs.

5 Person Responsible Rigging and Lifting Engineer-Lift Consultant Experienced Field Rigger Responsibility Conduct periodic safety audits of Crane/Lifting Contractors using Field Safety audit forms or the DASH process. Review Crane company operator certifications as part of prequalification paperwork. Ensure that all planned lifts are correctly designed and instructions clearly documented when required for Critical Lifts. Shall be utilized on : 1. Critical or Engineered Lifts 2. The competent person may be a mechanical, civil or structural engineer. 3. Or the person may have adequate time serving in this capacity for a period of at least 15 years in rigging and lifting experience. A person who has the experience to safely perform the work he is assigned and who has been designated by his contract company. The experienced Field Rigger will be required to carry or be placed on file documentation showing his company s designation as an experienced Field Rigger and documentation that he has completed awareness training as defined under OSHA 29CFR (f) riggers. Will be part of the Rigging Lifting plan discussion, review and approval. Crane Operator All Crane operators must meet State and/or national certification/license requirements and have a license issued by the National commission for the Certification of Crane Operators or other approved licensing organization. Accreditation by a local body of the International Union of Operating Engineers is acceptable. Operator s shall be able to provide their certification upon request. Should Crane Operators be required to operate more than one crane on the site, the contractor shall ensure the operator undergoes a competency assessment on each of the crane types he is expected to operate to ensure he is familiar with the functions, control and safety devices of that machine. Will be part of the Rigging Lifting plan discussion, review and approval Signal Person A designated person trained and experienced in the hand signals used and understood by the crane operators on the job. One designated signal person will be responsible for the control and coordination of any particular rigging and lifting activity. Under certain conditions, such as lifting in the blind or using multiple cranes, additional signal personnel may be required. In that case a Lead Signal Person must be designated. All other Signal Persons will be directed and coordinated by the lead. Should wear a distinctive vest at all times when they are performing the signaling function to the crane operator. If radios are being used to deliver signals to the crane operator and from the operator to the riggers, the radios shall be channeled independently so as to avert the possibility of interference with communications. 5.0 Procedure The following sections detail general crane work rules, safety equipment, training, and resource guidelines for contractors in the Kankakee facility.

6 5.1 Authorizations for lifts Step Action Person Responsible 1 Determine approximate location(s) for lifts. Contract Initiator Determine locations on Kankakee Site Wide Plot Plan. Secure Coordinate Locations from Drawings Coordinator Proceed to the lifting location(s) and note soil or surface grade in location. Note proximity of lifting location to surrounding tanks and contents. Note proximity to operating equipment that will be in operation during lifting operations. Note proximity to power lines. Note that in some cases power lines may not be supported on typical power poles. Underground utilities. Discuss the need for any inspections of equipment lift points with Mechanical Integrity Engineer or Reliability Engineer before scheduling lift. Determine the type of lift being performed. If it is a Non-critical, no permit required, you are done. If any other type of lift, secure a Rigging and Lifting Permit, Attachment and begin filling in the required information. Determine if any horizontal rotation actions are required. 2 Determine if there is a load bearing capacity rating for the soil or surface grade in location, please record on Rigging and Lifting Permit, Attachment If the lift is a Critical lift over 25 tons, you will have to employ a Rigging and Lifting Consultant to further complete a lifting plan. If the lift is a Non-Critical Lift, permit Required a copy of the un-approved Rigging and Lifting Permit form should be provided to the lift contractor so that they can use the provided information in their plan and calculations. Determine if the lift will involve Horizontal rotation. If horizontal rotation activities are planned a documented lift plan will be required. This plan then must be agreed to by the Rigging Supervisor, Lifting Equipment Operator and the Permit Issuer. Contract Initiator 3 Complete the Rigging and Lifting Permit Form. If the lift will occur over live equipment or hazardous chemical storage, secure approval by Operation Unit Manager/Superintendent. Live equipment will include Contract Initiator/Area Management

7 Step Action Person Responsible an exclusion zone around the equipment the size of the lifting equipment boom length such that if the boom or load were to fall, the live equipment would not be struck. Document this approval on Section I of the Rigging and Lifting Permit in the box titled Co-Area(s) and Co-Signature or Area management (Live Equipment Lift) Also Check the box at the top of the permit next to Lift Over Live Equipment. Determine if the lift will involve Horizontal rotation. If horizontal rotation activities are planned a documented lift plan will be required. This plan then must be agreed to by the Rigging Supervisor, Lifting Equipment Operator and the Permit Issuer. Check the box on the permit and note considerations located on the back of the permit form. 4 Fill out the rest of the information as required on the Rigging and Lifting Permit. Contract Initiator/Safety Specialist If the Lift is a Critical Lift the Rigging and Lifting Permit should be submitted to the Safety Coordinator only after the Contract Initiator has received a copy of the lift plan/calculations from the lifting Contractor. A Critical Lift Study or lifting plan must be attached to the permit. Take the Rigging and Lifting Permit to the Safety Specialist for their approval. Forward a copy to Safety, to Project Engineering and provide a copy to the lifting contractor to be supplied to the BASF Safe Work Permit Issuer. 5.2 Lift Protocols Prior to performing a lift at the Kankakee site, all Contract employees must be trained in the hazards of the lift area. Lifting Contractor work may proceed only after all three levels of training have been completed and the proper level of lift permit is completed: 1. Non-Critical Lifts, no permit required: Lifts under 2500 lbs including rigging and tackle. Lifts not over or not within the minimum required clearance of power lines as defined in Table Lifts not over piping, tanks or equipment containing hazardous chemicals. All lifting activities must be provided with a hazardous area zone, appropriately marked with red tape and displaying signage indicating the work going on and an up to date list of authorized entrants. a. The lifting plan shall be discussed between the Lifting Equipment Operator, Rigging Supervisor, and the Safe Work Permit issuer. Any changes to the original lifting plan, requires that a discussion take place among the stated parties and the permit be revalidated (Safe Work Permit). 2. Non-Critical Lifts, permit required: All loads below 25 tons are generally in this classification unless they fall into the exceptions as noted in the definitions of Critical or

8 Engineered Lifts Section 3.0. Lifts under this premise should be completed utilizing the Rigging and Lifting Permit, Form This will ensure loads of this nature have been checked and assessed to ensure the safe execution of the lift. Generally Non-Critical Lifts are described as below: Any load with a total rigged weight less than 25 Tons. Any horizontal vessel or package that does not exceed a rigged weight of 25 tons inclusive of rigging where the pat of the lift and its final position is unobstructed by other equipment or structures. Any load that does not have an offset Center of Gravity. Center of gravity is usually marked on the drawings of any equipment from a vendor. However, pipe spools may be presented for erection with an unidentified Center of Gravity which must be assessed by the lifting contractor. Only one crane is required to execute the lift. A tailing crane is exempted if used for lifting equipment off of delivery vehicles only. Lifts over the rear/front (where applicable) of the crane that do not exceed 70% of the cranes rated capacity. Lifts over the side of the crane that do not exceed 70 % of the cranes rated capacity. Lifts that are not over any live operating equipment (which includes any equipment that has not been decommissioned or adequately locked out by operations) or closer than the distance that the crane boom would fall if it were to collapse in any horizontal or vertical plane from live power lines or facilities such as transformers and switch yards irrespective of voltage. Any lift described in this section, where there are no known underground services that may affect the stability of the crane before, during and after the lift. The competent rigger and crane operator shall confer and agree about the safest practical means of rigging and executing any non critical lift. Should there be any conflict or lack of agreement in the way in which the lift is to be rigged, lifted and or positioned, the task will cease and the contract initiator will assist in the assessment and the resolution to the issues. If the issues cannot be resolved, the assistance of a Third party Rigging and Lifting Engineer/Consultant will be employed to resolve the issue. The ultimate responsibility for the safety of all lifting activities resides with the lifting contract company. In all lifting activities Contractors shall have in place structured and documented check lists including basic lifting plans (subject to review by Kankakee Site personnel) that are to be completed prior to each lift and maintained in the crane cab. The lifting plan shall be discussed between the Lifting Equipment Operator, Rigging Supervisor, and the Rigging /Lifting Permit issuer. Any changes to the original lifting plan, requires that a discussion take place among the stated parties and the permit be revalidated. 2. Critical Lifts or Lifts of 25 tons-50 tons: Planning and execution of Critical Lifts in this range are the responsibility of the lifting contractor with inputs from a competent rigger, crane operator and any other persons deemed necessary. Review of the final critical lift study will be undertaken by the Contract Initiator, Permit Issuer and the Safety Specialist with input from the Operational Unit Manager or Superintendent:.

9 Critical Lifts are lifts that consist of a lifted weight greater than 25 tons but does not exceed 50 tons where the path of the lift and its final position is unobstructed by other equipment or structures. Any two crane lift (other than tailing cranes when removing equipment from a transportation trailer in a clear area). Any lift that 70% of the crane s rated capacity but does not exceed 85% of the equipment s rated capacity. Any lift where a crane is to work within a maximum boom/maximum radius configuration. Lifts and cranes maintain an exclusion zone of no less than the distance that the crane boom would fall if it were to collapse in any horizontal or vertical plane from live power lines or facilities such as transformers and switch yards irrespective of voltage unless such power sources have been insulated or isolated and proved dead. Lifts where the operator of the crane is situated in a blind spot while picking and or positioning the lift at its final placement point. Lifts in areas where there are interface issues such as Simultaneous Operations. The lifting contractor has the final responsibility for all planning and execution activities for critical lift and associated rigging operations. The Site Contract Initiator or Safety Specialist reserves the right to review any or all lifting plans /studies they feel are warranted In All lifting activities, Contractors shall have in place structured and documented check lists that are to be completed prior to each lift of which copies will be made and maintained in the crane cabin along with other documentation such as Safe Work Permits and Lifting Permits. The lifting plan shall be discussed between the Lifting Equipment Operator, Rigging Supervisor, and the Rigging /Lifting Permit issuer. Any changes to the original lifting plan, requires that a discussion take place among the stated parties and the permit be revalidated. Horizontal rotation activities on the load will require a documented (written) lift plan. 3. Engineered Lifts - Weights of 50 tons or greater: All lifts falling into this category require the use of a Rigging Lifting Engineer/Consultant to prepare a lifting study that must be reviewed/approved and followed by the Lifting Contractor and be reviewed by the Kankakee Site Contract Initiator and Safety Specialist or other appropriate personnel as detailed in Table Table : Engineered Lifts Lifts of all other equipment, modules, and structures exceeding the criteria for Critical Lifts Description Preparation and Review Procedure 1 All lifts to be executed over, adjacent to or in close proximity of any live plant that if all or any component failed would adversely affect the operational ability of the plant. Lifting/Rigging Plan(s) shall be submitted to the operations unit for review/comment/approval prior to the load or equipment being mobilized into the operational area. Reviewed by Contract Initiator, Engineering Services Manager and Manufacturing Manager, Safety specialist. 2 Lifts over 50 tons but not exceeding 100 tons in lifted weight. Prepared by lifting/transportation contractor, subcontractor. Review by the Contract Initiator and Safety Specialist. Lifts over 50 tons reviewed by Technical Engineering Services Manager and Senior Manufacturing Manager. 3 Lifts over 25 tons in structures Lifting/Rigging Plan(s) shall be submitted to the

10 Table : Engineered Lifts Lifts of all other equipment, modules, and structures exceeding the criteria for Critical Lifts Description Preparation and Review Procedure operations unit for review/comment/approval prior to the load or equipment being mobilized into the operational area. Reviewed by Contract Initiator, Technical Engineering Services Manager and Senior Manufacturing Manager 4 Lifts by special lifting equipment such as jacking systems, slide systems, rolling. Lifting/Rigging Plan(s) shall be submitted to the operations unit for review/comment/approval prior to the load or equipment being mobilized into the operational area. Reviewed by Contract Initiator, Technical Engineering Services Manager and 5 Multi-Crane Lifts over operating facilities. Senior Manufacturing Manager, Safety specialist. Lifting/Rigging Plan(s) shall be submitted to the operations unit for review/comment/approval prior to the load or equipment being mobilized into the operational area. Reviewed by Contract Initiator, Technical Engineering Services Manager and Senior Manufacturing Manager, Safety specialist. 6 Lifts 100 tons or greater Prepared by lifting/transportation contractor, subcontractor. Review by the Contract Initiator, Technical Engineering Services Manager, Senior Manufacturing Manager, Site Director and Safety Specialist. Lift plan signed off by a qualified Professional Engineer registered in the state of Illinois. 5.3 Standard Specifications for Lifting Activities All lifting activities incur a degree of risk. This risk can be managed to reduce it to an acceptable level approaching zero by the proper amount of planning followed by strict adherence to safety policies, procedures and accepted best lifting practices. Depending upon the category of lift, a different level of study is required. All lifts at a minimum will need to meet the requirements for a Non-Critical Lift. Fully documented studies may be required for Critical or Engineered Lifts. a) For lifts deemed Non-Critical-permit required the completion of the Attachment Rigging and Lifting Permit is all that is formally (documentation) required prior to the lift. The lifting plan shall be discussed between the Lifting Equipment Operator, Rigging Supervisor, and the Rigging /Lifting Permit issuer. Any changes to the original lifting plan, requires that a discussion take place among the stated parties and the permit be revalidated. Horizontal rotation activities on the load will require a documented lift plan. Discuss the need for any inspections of equipment lift points with Mechanical Integrity Engineer or Reliability Engineer before scheduling lift. b) All critical and engineered lifts require a more documented lift study. The detail of the lift study for critical and engineered lifts should increase with the lifted weight or other complexities of the lift increasing. c) A load in excess of 85 % of the crane capacity at operational radius for the crane configuration. d) Multiple crane operations performed simultaneously which shall include tailing (other than simple unloading of equipment) and equalizer beam operations.

11 e) Any load with an irregular shape/attachment points and eccentric center of gravity. Piping spools that are of an odd shape or have an undefined center of Gravity shall be assessed and where necessary subjected to a documented lift study. The lifting contractor in conjunction with the Contract Initiator may make this determination. f) Any load elevated above, passing over or adjacent to a live facility, plant or hazardous chemical storage area. Adjacent shall be defined as the area that could be struck if the boom or load were to fail and fall to grade (collapse radius). g) An operation requiring suspended load transfer. h) An operation where the load utilized an equalizing beam. i) An operation of a load or direction by Spotter/Signalman/Rigger not in clear sight of the crane operator. j) Lifting in an area of soft ground condition and/or sloping terrain. k) Multiple equipment lifts may use the maximum boom length and maximum weight of a unique equipment piece for weight calculations. However, a list of all weights must be provided for each piece of equipment. 5.4 Documented Lift Study Information Requirements A documented lift study shall include the provision of, and not be limited to the following information. Lift Plan Detailed and concise method statement Job Hazard Analysis Crane Support Conditions Crane Assembly and boom lay down Appropriate Load chart of the machine(s) to be used in the lift. Crane range chart to determine head clearance and likelihood of coming into contact with the underside of the boom with the load. As a rule all lifts shall have an exclusion zone between it and the underside of the boom of at least 3 feet. Rigging tackle diagram Back up calculations and information Inspection reports for lifting attachments Certification and examination of cranes, rigging, tackle, etc. Operator s qualifications. Pre-lift checklist. Load supports, cribbing supports, load lay down area. 5.5 Lifting Plan The lifting Plan shall detail in plan and elevation, to a suitable scale on an appropriate plot layout: The precise (manufacturer s model number) crane and equipment to be used, not a generic type. The exact configuration of the crane, e.g. boom length, boom angle, mast length, counterweight, outriggers fully extended or tracks extended or retracted. Load delivery and placement location. Transportation equipment outlined for delivery of load, and include the exit route. Accurate diagram of the load including dressing. Position of the center of gravity of the load.

12 Physical position of the crane and load locations. Radius and capacity at pick and placement. Accurate load assessment including weight of the hook, block, rigging etc. In the case of multiple crane lifts, an assessment of the load share at all stages of the operation including any requirement for de-rating of capacity charts. Ground (soil) bearing pressure or outrigger loading for the crane together with resultant due to distribution system or foundation. Acceptable ground pressure bearing pressure for the crane operational area. Plot orientation (plant North). Actual ground conditions and profiles as they exit. Location of tailing crane. Location of access equipment and/or assist crane. Location of supports (temporary saddles) to complete dressing. Detail any specific access required other than that provided by an assist crane. Layout should show all temporary works plus other construction activities in the area. Location of underground services within 6 feet of the cranes tracks or outrigger pads. Clearances to the load, parts of the crane etc. during all stages of the operation. All items offering potential obstruction. Maximum wind speed for the operation. Safety exclusion zone to be determined. Night/day lift designation 5.6 Method Statement (Lifting Plan) A concise method statement shall be prepared that considers all stages of an operation on a step by step basis including the following: Detail clearly each stage and step of an operation. Preparation work relating to a lift operation. Dressing requirement and completion prior to lifting. Detailing tandem lift operations including monitoring of hoist wire verticality. Detail the removal of saddles, etc. below suspended loads. Detail the responsible person for the operation. Communication method for an operation together with back-up procedure. The method of controlling a lifted item. Assessment of access requirements to rig and d-rig the load. Consider the interfaces between associated parties involved with a lift. Define when responsibility for the load reverts from the lifter to installer. Arrangements for monitoring the wind and weather conditions. Establishment of exclusion zone and controlling entry. Contingency planning such as lighting requirements. Assessment of resources for an operation defining their location as necessary.

13 Calibration/functional certificates the crane load cell and anti two block safety devices. Requirement for Safe Work Permit and Rigging and Lifting Permit. 5.7 Job Hazard Analysis (Pre-Task Planning and Lifting Plans) The Pre-Task Planning or Lifting Plan (Job Hazard Analysis) shall recognize all elements of foreseeable risk inherent in an operation and satisfactorily address them thus ensuring that safety is not compromised. This shall include the following, but is not limited to: Ground conditions and crane support Crane and rigging suitability. Structural capability of the load. Direction of an operation and control of the load. Discussion about load supports, support and stability of cribbing, horizontal rotation requirements, where horizontal requirements are to take place (these should only take place at a minimally elevated position and any cribbing fully supported). Personnel not being subjected to location/working below a suspended load. Interface with other contractors. Access to/from lifting attachments. Interface with the Manufacturing personnel (where required). Safety procedures. Exclusion zone. PPE Hazards of horizontal rotations if required. 5.8 Crane Support Conditions This is to assure that information is available to fully consider the best method to support the crane: Site investigations or reports on ground capacity. Detail of distribution system for crane loading/ground bearing pressure calculations. Layout of crane supports. Location of underground services. Design and detail of specific crane supports. 5.9 Crane Assembly and Boom Lay Down The area required to assemble the crane and store components may need to be defined. Area to be kept clear for boom lay down due to weather conditions Rigging Tackle Diagram Provide rigging diagrams which clearly details the full complement of tackle required for attachment to the load from the crane hook: Full rigging indicating slings, shackles, lifting beams, etc. to be used for each lift.

14 Detailed information of the rigging including sling diameter, SWL or WLL capacity and length of sling. Type and capacity of shackle. Length of lifting beam centers and capacity. Any adjustment necessary for eccentric center of gravity detailing how achieved. Hook block capacity, type and number of parts of rope in the reeving. Geometry of the rigging Manufacturer s and Engineering Calculations and Information Manufacturer s details and capacity charts. Manufacturer s crane loading on crawlers/outriggers. Line pull of hoist wire. Ground bearing conditions. Confirmation of the load and center of gravity. Calculation of the share of load on each crane. Lift criteria for inclusion in the design. Structural design of lifting attachments. Calculation of loads in each part of the rigging due to the geometry. Bending efficiency for rigging around relatively small radii. Transfer of load between cranes during up-ending and multiple crane activities. Limiting wind speed based on load sail area Inspection Reports for Lifting Attachments Confirmation that inspections have been completed for attachments: Visual inspection reports. Applicable NDE reports such as dye-penetrate, mag Particle (MP), UT, Radiography Visual inspection of lifting attachments on equipment arrival. Any damage identified to lift attachments will terminate their use. They must be replaced with un-damaged attachments with documented inspection reports Certification of Inspection and Examination of Cranes and Rigging All cranes and lifting equipment, gear, tackle, etc. will be provided with certificates and subject to periodic inspection as follows: Annual inspection report for cranes as required by OSHA Rope certificate showing the proof load weight and breaking strain Valid governmental Inspection/certificate for the crane to operate. Semi annual inspection report for crane. Daily/weekly inspection reports Maintenance records for major equipment. Original proof load test certificate of rigging and tackle including slings, shackles, chains, etc. FSWR certificate giving breaking strength of the wire used for the slings A certificate of Proof Load Test for slings, shackles, etc. Periodic inspections of rigging and tackle.

15 Original load certificate of spreader, equalizer or lifting beams. Semi annual inspections of spreader/lifter beams Lifts over or near Energized Electrical Power Lines Lift plans and risk assessments shall be prepared by the lifting/crane contractor for all lifting activities within 20 feet of any vertical or horizontal plane in the case of energized 220 volts and above electrical power lines. The lift plan shall include completion of the Electrical hazards Checklist form. Table : Safe Working Distances, Lines should be pigged if less than 20 feet. Voltage (Phase to Phase) Minimum Required Clearance (kv) (ft) Operation Near High Voltage Power Lines Up to ft 0 in Over 50 to ft 0 in Operation in Transit with No Load and Boom or Mast Lowered Up to ft 0 in Over 0.75 to 50 6 ft 0 in Over 50 to ft 0 in NOTE: Environmental conditions such as fog, wind, precipitation or snow may require increased clearances. This shall be discussed and agreed upon during the pre-task planning and permitting process Lifts over or near Live Process Lines, equipment and buried services. In the case of work in close proximity to Operational plant, equipment and buried services the activity shall be covered under a Safe Work Permit, Rigging and Lift Permit and Manufacturing Manager approval for the area. A lift over live equipment checklist must be completed and submitted with all other information concerning the lift when applying for the Safe Work and Rigging and Lifting Permits. A safety watch/signal person shall be present for all lifts near power lines Environmental Restrictions All lifts are restricted to sustained wind velocities of 20 MPH or less, unless engineered to accommodate and approved by the Contract Initiator, Technical Engineering Services Manager, Safety Specialist, Senior Manufacturing Area Manager, and Permit Issuer. Visible Lightning will immediately suspend the Rigging and Lifting Permit Other Restrictions Placement and use of all cranes, transportation, specialty lifting equipment and rigging components shall be in accordance with manufacturer s procedures and industry standards. In no case shall such equipment be loaded beyond their rated capacity imposed by the manufacturer s or other applicable safety standards.

16 Cranes, transportation, specialty lifting equipment, and rigging components shall not be modified, altered or repaired without the manufacturer s approval. All such repairs and/or repairs shall be documented according to the manufacturer s procedures or guidelines. Under no circumstances shall lifting components such as lugs, trunions, spreader or lifting beams be manufactured onsite. Assembly/disassembly of the cranes, as well as lattice boom changing shall follow manufacturer s instructions. Federal Aviation Administration (FAA) Regulations Part 77 shall be met by the Crane s owner. FAA permitting will be completed by the lifting contractor. This includes the requirement that 30 days notification to the local FAA office for the erection of any structure (including crane boom, lifting system, etc. ) higher than 150 feet above ground level or 100 feet above ground level, if within 20,000 feet (about 3.8 miles) of an airport. The Greater Kankakee airport (GKA) is within this distance from the BASF Kankakee plant. All cranes should be inspected before use at the Kankakee site. Cranes found to be defective in any way shall not be used and shall be removed and replaced by acceptable cranes. When brought onto site, each crane shall have a copy of its last (current) ASME B30.5 periodic (annual) crane inspections. Daily routine inspections shall be performed by the crane operator and documented in the crane s daily log book. All Inspections may be audited by Kankakee Site Personnel while the crane is onsite. Daily inspections should include: o All controls and safety devices o If any controls do not operate properly, the crane must be removed from service and repaired or replaced. o Crane operators must also inspect the work location for unsafe conditions. If unsafe conditions are found, the crane operator must not operate the crane until the conditions are corrected. Functional testing shall be performed when the crane arrives onsite, prior to starting work: o All load indicating devices are working properly and accuracy of the load indicator is within tolerance. o The overload function for each drum is working properly and will disengage when the maximum radius is reached for the load being lifted (if crane is equipped with a Load Moment System Overload Cut-off Device). o Boom will telescope in and out, and boom up and down. o In the case of lattice boom cranes, the boom stop safety device is free from damage and is operational. o Brakes release smoothly and are capable of holding the load. o Crane is stable at the minimum, maximum and throughout its operating radii. o Both the load block on the main hoist line and overhaul ball on the whip line shall be raised to the maximum height to ensure that the anti-two block device will either warn the operator of the limit of hoisting, or will kick out the hoisting function. o Crane can perform designed multi-function operations, i.e. swing, hoist and boom, etc. o Operator is competent and familiar with machine, including the safety systems and is fully capable of reading and understanding the load charts. All load charts shall be in English.

17 o All cranes shall be subject to ASME B30.5 (B30.3) frequent inspection with a maximum of one month interval between inspections. o Cranes shall have an anti-two-block device or two-block warning/preventions features. o One of three overload cut-off devices: load indicator, rated capacity indicator, or rated capacity load limiter. o No crane shall lift any load in any configuration unless there is a current capacity chart in or on the crane Standard Rigging Components are off the shelf tackle, rigging and other similar rigging components. The capacity or size of the rigging components shall not be less than that specified on the lift drawings or plans if applicable. Standard rigging components shall not be loaded beyond their rated capacity and shall be used in accordance with manufacturer s recommendations. The rated capacity of a sling whose body is bend around a pin, crane hook, or any other object shall be reduced in accordance with the Wire Rope Efficiency Chart, see attachment Table : Wire Rope Slings in Choker Hitch Pin diameter should be at least 90% of the diameter of the pin hole. The following rule of thumb shall apply: for pin holes less than four inches diameter, the pin diameter could be 1/8 inch smaller. In cases where a hole diameter equal to or greater than four inches diameter, the pin diameter could be ¼ inch smaller. Exposed or unprotected carbon steel slings and rigging hardware shall not be permitted to come into contact with stainless steel or non-ferrous plant equipment except at the pin holes of lifting lugs. Synthetic fiber slings (web or round) shall be protected from cutting and sharp edges. All protrusions and abrasive surfaces should be kept from contact with the sling. Where unavoidable situations develop padding shall be placed between the sling and the load. A rigging engineer shall review and approve any use of a synthetic web sling, when protected padding is required. Temporary wood softeners, or other approved alternate, shall be used to protect lifted equipment from damage due to concentrated bearing points and movement of rigging hardware. Wood or other materials used as softeners shall be attached to the load or slings by a lanyard to prevent the softeners from dropping from height when the crane releases the weight of the load when the lift is completed. Finish painted surfaces are to be further protected from discoloration, scratches, gouges, and other effects of direct contact with slings and rigging hardware. All slings shall be marked in accordance with ASME B30.9. All Rigging components shall be regularly inspected in accordance with the requirements of ASME B30 for frequent and periodic inspections and removed from the job site if they fail to meet the minimum requirements of ASME B30. Use of Synthetic Slings. o All slings shall be used in direct compliance with manufacturer s conditions of use and recommendations.

18 o Slings shall be inspected prior to every use. o (Endless Round Slings) Any tears, cuts, abrasions, or evidence of the material being contaminated with any oils or alkalis to the outer casing of round slings shall be cause for rejection of the sling for use. Any burns in the sling from direct heat, weld slag or grinding residue shall be cause for rejection. o (Webbing Slings and Round Slings with Eyes). Any damage such as cuts, abrasions, tears or damage to the body or the eyes of a webbing sling shall be cause for rejection of that sling. Webbing slings that have been contaminated with oils, alkalis, metal filling or exposed to heat (burns or scorches) shall also be rejected. Some manufacturers have sewn a red thread into the side of webbing slings as an additional safety measure once this thread is exposed the sling is condemned. o Webbing and round slings shall not be used in places where they are subject to being cut or damaged by surrounding material or structures. o Whenever round or webbing slings are used in a choked configuration around material other than pipe or round surfaces they must be adequately protected, timber softener s are not an option with these slings because of the risk of the timber splitting and cutting the sling with the resultant splintering. o Slings used in a choke configuration shall have the choke at a normal 120 degree angle. It is prohibited to strike the sling eyes with any material to close the angle further once weight is applied by the crane or lifting device. o Round or webbing sling shall not be assembled on any hook or in any shackle with Wire Rope Slings. o Round or webbing slings shall not be exposed to temperatures below -40F or above 176F. o Lifting of rebar with webbing or round slings shall only be approved for slings fitted with additional leather or similar protection for the sling surfaces that come into contact with the steel rebar. o Lifting with round or webbing slings with eyes in multiple leg configuration shall be restricted to the included angle depicted by the manufacturer (whether that be 90 or 120 degrees) with sling eyes(where more than two slings are used) supported by an appropriately sized bow shackle. o Slings when not in used shall be stored correctly and not left laying in the direct sunlight, in the dirt or where there is any build up of oils that may contaminate the sling. o Slings shall not be shortened or joined together by knotting, tying or reeving the eyes. o Any sling that has been subjected to shock loading shall be removed from service and destroyed. o Sling shall not be used in close proximity to welding, cutting or grinding activities. o Tag lines shall be used on all loads that are to be raised above shoulder height of the individual controlling it. o Slings shall not be dragged out from under any load with the crane or other mechanical device.

19 o Slings that do not have the Safe Working Load (SWL) tag attached to it shall be removed from service. Crane Hooks o A manufacturer s cut sheet showing the safe working load and the full dimensional details of dimensional checks of each hook shall be available for review. o Inspection and dimensional check of the hook should include: Check for distortion of the hook, such as bending, twisting, or increased throat opening. Check for wear, includes a full dimensional check. Check for cracks, severe nicks, or gouges. Check to see if the latch is closing properly. Check to see that the means of attaching the hook to the block is secure. Hooks failing the above shall be removed from service Permits No contract employee is allowed to begin work without the appropriate permit as described below: Permit Safe/Hot Work Permit Work Order Lock Out/ Tag Out (LOTO) Rigging and Lifting Permit BASF EHS Description Procedure # All work must be properly classified in accordance with EHS Procedure Safe Work/Hot Work, Section 5.1. Once classified the appropriate work orders and/or work permits can be issued. Any work completed by contractors that is not classified or scheduled through the maintenance work order system will require a safe work permit at a minimum. Safe Work/Hot Work permits will be issued by authorized Permit Issuers when the work scope requires it. Work orders can be authorized by the operator of the equipment Lock Out Tag Out permits will be issued by area production personnel for the control of hazardous energy before work begins. Each contract employee to perform work on equipment that is locked or tagged out must place their own personal lock (identified with their name) on the lock box before work begins Attachment 1 to this procedure. The Rigging and Lifting Permit shall always be completed for any Rigging and Lifting being performed in a maintenance/project engineering functions within the facility per the restrictions and exclusions of the procedure.