operation lift plan... · web viewthis document aims to provide a detailed description of all the...

Petroleum Development Oman L.L.C.

Standard Hoisting Plan for winch line operations

On Drilling Rigs, Hoists & Stand alone Units.

Master Copy – Printed copies of this document are UNCONTROLLED 1

TABLE OF CONTENTSS

1.0 Introduction.................................................................................................................................................... 3

1.1 Aim.......................................................................................................................................................... 3

1.2 Priority..................................................................................................................................................... 3

1.3 References............................................................................................................................................. 3

1.4 Scope....................................................................................................................................................... 3

2.0 Roles and Responsible.................................................................................................................................. 3

2.1 Overview................................................................................................................................................... 3

2.2 Person In Charge...................................................................................................................................... 3

2.3 Banksman (Floor man)............................................................................................................................. 4

2.4 Winch Operator (Driller)............................................................................................................................ 4

2.5 Riggers (Roustabout/Floor man)............................................................................................................... 4

3.0 Pre-lift requirements....................................................................................................................................... 5

4.0 Winch Lifting Operations checklist (Not Exhaustive)...................................................................................... 5

5.0 Lifting Equipment details................................................................................................................................ 6

5.1 Winch details ............................................................................................................................................6

5.2 Accessories details....................................................................................................................................6

5.3 Personnel details: .....................................................................................................................................6

6.0 Steps taken to eliminate danger to all personnel ...........................................................................................6

7.0 Task details (step by step)..............................................................................................................................6

7.1 Lift from Hoist / Rig Floor onto the ground ...............................................................................................6

7.2 Lift from ground onto the Hoist / Rig Floor ................................................................................................7

8.0 Lift Plan...........................................................................................................................................................8

8.1 Sketches of the operation ........................................................................................................................ 8

09.0 Hand Signals.................................................................................................................................................9

10.0 10 Questions For The Safe Lift ................................................................................................................. 10

11.0 Task Risk Assessment Worksheet ........................................................................................................... 11

1.0 Introduction


1.1 Aim

This document aims to provide a detailed description of all the planning and execution requirements for conducting all types of winch hoist operation in all PDO and its contractor’s locations. PDO Well Engineering specifically Rigs, Hoists & Stand Alone Units.

1.2 Priority

The priority whilst conducting winch lifting operations such as this is to use qualified and experienced personnel, using

appropriate and correctly certified equipment following a planned method statement.This plan defines the roles, responsibilities, equipment and personnel requirements and the method to use to ensure the

operation is conducted without harm to personnel, or damage to the load’s, the lifting equipment, the asset or the environment.

1.3 References

This Lift Plan has been developed to align with the following International and PDO regulations:PDO Inspection, Certification Procedure – PR 1708PDO Procedure for Lifting Operations – PR 1709Any further client requirements differing from the above will be incorporated into this Lift Plan upon request.

1.4 Scope

The scope of this lift plan is to detail how the winch lifting operation will be planned and executed in safe way. Also it shows all the mandatory requirements that shall be followed during any type of winch lifting operation. It is mandatory for all PDO Well Engineering contractors (operating Rigs, Hoists & Stand Alone Units).

2.0 Roles and Responsibilities

2.1 Overview

The detailed on-site roles and responsibilities will be reviewed during the Tool Box Talk that will precede the series of

lifts. This section provides an overview of the personnel involved both off-site planning the operation and on-site conducting it.

2.2 Person In Charge (PIC) – (Driller)

- The Winch Operator is the Person in Charge (PIC) of this Hoisting operation.- The Person In Charge must review this document and collate all the appropriate documentation prior to the lifts

taking place for review by the appropriate personnel.- On-site, the PIC will supervise the lifting operations and ensure that all equipment are pre-inspected and that those

inspections are documented, that the lifts are all conducted in accordance with the Lift Plan and that the control and positioning of all personnel during the lifts is appropriate and safe.

- The PIC will lead the Tool Box Talk, explaining the roles and responsibilities of all personnel involved with the lift,

ensuring that all personnel fully understand by actively involving them in the discussion. He will review this Lift

Plan, communicate the control measures identified in the Task Specific Risk Assessment and confirm the 10

Questions for a Safe Lift have been asked and are answered appropriately.- He will ensure that all personnel on-site are wearing the appropriate PPE.- He will positively reinforce the fact that all personnel have both the right and the responsibility to STOP THE JOB at

any time if they identify an unsafe act or condition


- He will ensure that the area of the lift is cordoned off with physical barriers to prevent personnel not involved in the lift becoming positioned in the danger area.

- He will check the area of the lift for adjacent, overhead or underground hazards.- He will supervise the Before Use Inspections on the winch and Hoisting Accessories ensuring that all checks are

conducted to the appropriate standard and correctly documented.- He will check that the environmental conditions are acceptable in line with this Lift Plan to proceed with the lift

(wind speed, weather and light).- He will supervise the Banksman, the winch operator and the Riggers whilst they are conducting the lift.

2.3 Banksman (Floor man)

- The Banksman will attend and actively participate in the Tool Box Talk.- The Banksman will insure that the lifted load is properly positioned straight under the winch hook. - The Banksman will be easily identifiable throughout the lift by wearing a hi-visible vest. - He will agree the signals to be used with the Winch Operator and the Riggers and will stress the importance of the

Emergency Stop Signal.- The Banksman will control the positioning of all personnel throughout the execution of the lift.- He will maintain a position where he can see all personnel involved in the operation; and they can see him.- The Banksman will be under no time pressure. He must follow the Lift Plan serial by serial; if at any time the

operation is required to differ from the Lift Plan he will STOP THE JOB, review the plan and brief all parties prior to proceeding.

2.4 Winch Operator (Driller)

- The Winch Operator is the Person in Charge (PIC) of this Hoisting operation.- The Winch Operator will conduct a thorough Before Use Inspection on his winch and lifting accessories; he will

document this inspection.- The Winch Operator will attend and actively participate in the Tool Box Talk.- The Winch Operator will keep the winch ready and waits the signal from the Banksman.- The Winch Operator will check the lift he is expected to conduct against winch (SWL); if it is more than the normal

(SWL) he will inform the Person in Charge prior to commencement of the lift.- The Winch Operator will fully deploy his winch for operation when told to do so by the Banksman. This includes

fully deploying of conducting all Before Use checks.- Only personnel with the winch operator’s direct permission are permitted to be around the winch.- The Winch Operator will follow the directions of the Banksman only at all times throughout the duration of the lift;

the only exception to this is if he is given an Emergency Stop signal. He will immediately conduct an Emergency Stop without question.

- At no time is the Winch Operator permitted to leave his winch unattended whilst it is deployed.

2.5 Riggers (Roustabout/Floor man)

- The Riggers will conduct a thorough Before Use Inspection of the lifting accessories to be used for the lift; they will record this inspection.

- The Riggers will attend and actively participate in the Tool Box Talk.- At any time during the operation, if they do not understand what is expected of them they must ask. If this requires

them to STOP THE JOB, then this is what they must do.- The Riggers will follow the instructions of the Banksman at all times. They will only approach the load when told to

do so.- They will never touch a suspended load unless it is below knee level. They must never stand under a suspended load

or in a position where they could potentially be harmed if the load were to swing.- If they are required to come close to the winch, they must take the permission of winch operator.


- They must always have the Winch Operator’s permission prior to do anything if they are no sure about it.- If they are required to climb for any reason, they must use the steps provided and never jump off.- The Riggers will be under no time pressure. If at any time they identify an unsafe act or condition they must STOP

THE JOB. This is the only time they are permitted to give signals to the Winch Operator.

3.0 Pre-lift requirements:

1. Confirm all required lifts covered by this lift plan and pre lift check completed.2. Confirm all Before Use checks have been completed and recorded correctly. 3. Check Wind Speed is within limits and environmental conditions are acceptable4. Ensure pre-lift checks and visual inspections on winch, lifting accessories, the load lifting points and lifting crew

certifications have been completed by LEC.5. All the used safety Harness shall be certified, if it is required. 6. Ensure the following have been covered during Tool Box Talk:

- TRIC has been fully completed.- The associated Task Risk Assessments have been identified.- The Rules & Responsibilities are understood to all personnel involved.- 10 questions for the safe life have been discussed. - The lift plan is clear to all participants.- The used method(s) of communication (Radio / Verbal / Hand Signals) must be confirmed.

7. Ensure Banksman is easily recognizable with a high visibility vest.8. Ensure that Working at Heights rules are understood by all relevant personnel9. Ensure that the lifted load will never Touch or come close to the structure. It shall move freely.10. Barrier off area - Ensure only essential personnel are in the Hoisting operation area11. Ensure all personnel involved with the operation are ready to commence the lift.12. Check for loose objects ( Confirm & secure any loose items )13. Verify with Winch Operator, banks man and handler that all checks are complete and ready.14. Ensure that the correct tag line is used and that the load can be controlled by the tag line.

4.0 Winch Hoisting Operations checklist (Not Exhaustive):

Cultural, communication and language difficulties Weight, size, shape and centre of gravity of load Fragile load Load has any sharp edges Availability of approved lifting points on load and visually inspected prior to lift Method of slinging/attaching/detaching the load Lifting through substantial height Need for tag lines (100% requirement). Suitability and condition of lifting equipment to be used Initial and final load positions and how it will get there, lay-down area is within operating radius of winch Lifting path free from any obstacles. Is suitable packing available for protection of load/slings while landing the load Number and duration of lift(s) Conflicting tasks in area Environmental conditions including weather and permissible limits Lighting in the pick-up and lay-down areas; Proximity hazards, obstructions. Working under suspended loads barriers in place Access and emergency escape routes


Experience, competence and training of personnel Minimum number of personnel required for task Pre-Use Inspection of equipment by winch operator Visibility of the load by Banksman. Color coding implemented correctly. Will the Banksman always be visible to winch operator or has an alternative method of communication (eg.

radios) been established.

5.0 Lifting Equipment details:

5.1 Winch details

Type Max Load to be Lifted (kg) 80% of SWLSWL Serial NumberModel Utilization % of capacity of winch

5.2 Accessories details:

Equipment SWL ID NO. Inspection date Expiry date Proof load (If required) Certificate NO.WinchWebbing Sling1Webbing Sling2Wire Rope1Wire Rope2Bow Shackle1Bow Shackle2

5.3 Personnel details:

Person Permit No. Issue date Expiry dateBanksman Winch Operator (PIC)Riggers

6.0 Steps taken to eliminate danger to all personnel:

Risk Assessments Tool Box Talk Lift Plan Supervision Barriers No conflicting operations in the same area

Level of Operational Control: No Permit to Work Job Banksman OnlyEngineering support required: Yes NO

7.0 Task details (step by step):7.1 Lift from Hoist / Rig Floor onto the ground

1. Winch operator holds the TRIC with all involved in the Hoist. For change out new TRIC shall be held2. Rigger visually checks all lifting gears.3. Winch operator ensures Tag line is available with good condition.4. Rigger attaches the load to the winch line.5. Rigger to attach the tag line to the winch line / or load6. Banksmen ensure that all the time the tag line handled by the Roustabout on the floor/ground.7. Banksmen steps back out of the potential red Zone


8. Banksmen ensures visual contact between Winch operator and him9. Banksmen ensures visual contact between Roustabout on the ground and him10. Banksmen confirms readiness of Roustabout and Winch Operator11. Banksmen provides signal to winch operator to lift load approx. 50 cm (0.5 meter) above the Hoist / Rig floor12. Banksmen to check Center of Gravity of load 13. Banksmen to check that load can be guided by Tag line securely 14. Banksmen to give the signal to lower the load onto the ground15. Rigger to confirm secure landing of the load to Banksmen16. Banksmen to signal Winch operator when winch line is sufficient slack to remove lifting gear from the load17. Banksmen to ensure Winch operator has understood the signal to stop winch operations18. Banksmen to signal the Rigger to remove lifting gear from load19. Banksmen to receive confirmation from Roustabout that the winch line can be lifted up securely onto the Rig

Floor20. See 7.2

Note: The above can be amended time to time.

7.2 Lift from ground onto the Hoist / Rig Floor

1. Winch operator holds the TRIC with all involved in the Hoist. For change out new TRIC shall be held2. Rigger visually checks all lifting gear 3. Winch operator ensures Tag line is available for lowering the winch onto the ground see 7.1 (if winch line

needs to be lowered without load follow all steps except to attach the load)4. Banksmen ensure that all the time the tag line handled by the Roustabout on the floor/ground 5. Rigger attaches the load to the winch line.6. Banksmen to step out of the potential red zone7. Banksmen to ensure visual contact with Winch Operator8. Banksmen to ensure visual contact with Rigger.9. Banksmen confirms readiness of Rigger and Winch Operator.10. Banksmen provides signal to winch operator to lift load approx. 50 cm (0.5 meter) above the Hoist / Rig

floor11. Banksmen to check Center of Gravity of load 12. Banksmen to check that load can be guided by Tag line securely. 13. Banksmen to signal to hoist the load onto the Rig /Hoist floor14. Banskmen to ensure secure landing onto the Rig /Hoist floor 15. Banksmen to signal Winch operator when winch line is sufficient slack to remove lifting gear from the load16. Banksmen to ensure winch operator has understood the signal to stop winch operations.17. Banksmen to remove the lifting gear from the load18. Banksmen to secure the winch line hook.

Note: The above can be amended time to time.


8.0 Lift Plan (can be amended for each lifting operation):

8.1 Sketches of the operation (To be added)


9.0 Winch Hand Signals


10.0 10 Questions For The Safe Lift


Prior to any lift commencing, the Person in Charge must ask and be happy with the answer to the following 10 questions for a safe lift:

1. Is everyone aware of and do they fully understand the lifting and hoisting procedures applicable to the lift?

2. Has everyone attended the toolbox talk?3. Has a pre-use inspection of the Lifting Equipment been carried out and are the Lifting

Accessories tagged or marked with:a. Safe Working Loadb. A unique identification numberc. A valid certification date

4. Are all safety devices working?5. Does everyone know the Person-in-Charge of the lift?6. Is everyone competent and aware of his or her tasks?7. Is there a current Lift Plan and JHA and does everybody understand the job and precautions?8. Does everyone know the environmental limits (e.g. maximum permissible wind speed) for the lift?9. Is the lift area controlled and is everyone clear if the load falls or swings?10. Are signaling methods and communication agreed and clear to you?


11.0 Generic Task Risk Assessment: This is a generic task risk assessment. Each Individual needs to set up his own specific detailed task risk assessment that reflecting his work environment. The Risk Matrix needs to be done.

Task Potential Hazard Consequences Precautions (Controls) ResponsibilityGENERAL SAFETYPRECAUTIONS

Moving part hazard. To prevent serious injury andproperty damage

Do not operate or install winch without reading and understanding the

operator’s manual. Keep hands clear of wire rope, hook and fairlead opening during operation

and when spooling. Stand clear of wire rope and load during operation. Keep others away. Inspect winch installation and wire rope condition before operating winch. Do not use to move persons.Do not exceed winch’s rated capacity. Never touch wire rope or hook while in tension.Be certain the anchor you select will withstand load.Never wrap wire rope back onto itself.Use a choker chain, wire choker rope or tree truck protector on the anchor.Prior to initiating winching operation be sure any element which can interfere

with safe winching operations is removed.Take your time, sloppy rigging causes accidents.Know your winch; take the time to fully understand your winch and the

winching operation.Do not use winch to secure a load during transport.Do not submerse in water.Wear heavy leather gloves when handling the wire rope.Never winch with less than five (5) wraps of wire rope around the drum.

Winch Operator

OPERATOR/RIGGERS Untrained

Inexperienced

Impatience

No Safety Equipment or Attire

The load may not be prepared for winching properly.

The rope may not be properly attached to the load.

The load may not be secured properly for transport.

May be a danger to others.

Injury or Death

Read and understand the manual. Keep a copy with you for reference. If there is something you don’t understand “Do not guess” seek assistance

from experienced operators.

Be patient and assess the situation thoroughly.

Always use accredited and rated accessories e.g. hook chains etc.

Wear safety attire always.

Think safety first, middle and last.

Winch Operator

WINCH MOUNTING Winch mounted out of alignment.

Mounted so it is very difficult to remove or service

Mounting bolt may vibrate loose

Excessive wear on parts, may cause winch to seize,

winch may work inefficiently.

The harder the winch is to service, the less it may be

looked after and if the winch is impossible to be removed without destroying things, the less likely the

small problems will be fixed leading to a major failure.

Leading to stripped threads, oil leakage, winch damage

and potential failure

Think safety first, middle and last.Refer to the manual. It is critical the winch is set up correctly.

Fit the winch so it can easily be removed. Give thought for the service

engineer who has to check an add oil and grease and may have to remove

the winch for repair. It may cost a bit more now but easy accessibility will

save money and down time eventually.

Use Loctite 567 thread locker sealer or similar on mounting bots. Check periodically and or when recommended by the instructions.

Maintenance


Task Potential Hazard Consequences Precautions (Controls) ResponsibilityLUBRICATIONOIL & GREASE ARE

THE CHEAPEST COMPONENTOF THE WHOLE

UNIT YET CAN

CAUSE THE MOST

DAMAGE TO THE UNIT

Wrong oil

Low oil level

Too infrequently greased.

Laziness

May lead to breakdown of incompatible parts. May not have the correct properties to lubricate the unit efficiently enough causing eventual failure.

Insufficient lubrication of bearings, bushes etc. will cause breakages and eventual failure.

Eventual seizure to free- wheeling apparatus i.e. the drum will not free- wheel, the dog clutch will not engage or disengage etc. resulting in eventual failure.

Unit will run out of lubrication causing eventual

failure.

Check manual - seek manufacturer’s advice.

Check oil level regularly.

Grease frequently, more is best.

Check - fill and grease regularly.

Maintenance

COMMISSIONING OF WINCH

Excessive heat.

Bolts and fixtures not secured properly. Lack of lubrication. Dog clutch may not be engagedproperly

May cause damage.

Winch may become dislodged or move. Winch may

seize, dog clutch may slip.

When winding the rope on the drum for the first time, check for heat buildup.

Check the bolts are tensioned. Make sure the oil in the box is full. Grease the

nipples, especially on one in the winch drum. Move the dog in and out to get the feel. Listen for unusual noise.Most equipment requires a running in period so do not run the winch at full

speed for at least the first 30 minutes. Do not exceed half the rated load for the

first 30minutes. After one hour of operation check it all once more.

Maintenance

ENGAGING DOGCLUTCH MANUALLY

Not fully engaged.

Broken pins in selector fork.

Shock loading to the winch.

Excessive wear in clutch engagement mechanism

May cause winch breakage or load release.

Clutch handle becomes loose and free moving.

May cause limiting to the clutch movement because twisted shaft.

May cause load release

The winch may have a decent in the shaft which will be identified by a spring loaded ball that seats itself into the detent when engaged or disengaged. Make sure you feel the detent and ball make the connection.

If the handle is loose repair it. If the clutch is stiff grease it. If that doesn’t fix it make immediate repairs. Repairs should be carried out as soon as they become apparent. Do not wait. They may become life threatening. Remember safety, first, middle and last. Dog clutch locks are available. See manufacturer.

Winch Operator

ENGAGEMENT OF DOG CLUTCH – AIR OPERATED

Not fully engaged.

Broken pins in selector fork.

Shock loading to the winch.

Excessive wear in clutch engagement mechanism

Excessive pressure in air cylinder can lead to theabove hazards

SPECIAL FITTING CONSIDERATIONS

May cause winch breakage or load release.

Clutch handle becomes loose and free moving.

May cause limiting to the clutch movement because twisted shaft.

May cause load release

As aboveSEE “AIR RAM” SECTION IN MANUAL

If the handle is loose repair it.If the clutch is stiff grease it.If that doesn’t fix it make immediate repairs.Repairs should be carried out as soon as they become apparent. Do not wait. They may become life threatening. Remember safety, first, middle and last.Dog clutch locks are available. See manufacturer.

As above“AIR RAM” SEE SPECIAL NOTE

Winch Operator


Task Potential Hazard Consequences Precautions (Controls) ResponsibilityWIRE ROPE Frayed

Kinked

Over Size

Under Size

Breakage

Breakage - steel splinters when rope is being handled.

Breakage - kink may catch on things i.e. The end of the tray etc. Severely weakens rope.

Breakage - too big a rope wrapped around a small diameter drum will cause early fatigue.

Too small a rope may not meet rated capacity.

To have a rope break under load can be catastrophic. It can whip in any direction causing injury or death and may allow your load to run free to cause further havoc.

Replace

Replace

Replace. Always use recommended rope size.Seek advice from accredited wire rope manufacturer.

Replace. Always use recommended rope size.Seek advice from accredited wire rope manufacturer.

Replace. Never stand between the load and the winch always winch on level ground.Always wear safety attire/equipment on hands, feet body and eyes especially.

Winch Operator /

LEC

WINCHING LOADS

Winching on uneven ground.

Winching on a hill or slope.

Winching rolling loads.

Not preparing load for winching.

Shock loads

Load may winch on unevenly and fall.

Winching uphill may put far more load on your equipment than it is rated for.

Winching downhill may allow the load to over-run the rope resulting in the bird-nesting of you rope. (See “Rope consideration while winching” section)

The load may not be prepared for winching properly.

This type of load imposes a strain on the winch many times the actual weight of the load and can cause failure of the cable or of the winch.

Always load on the most level ground you can find and within reason, load across the hill so your load will not roll away if it becomes dislodged.

Be patient, be safe, and take a minute to analyze all the potential dangers.

Read and understand the manual. Keep a copy with you for reference.

Avoid shock loads at all costs. You must make sure that there is tension on the rope at all times whilst winching, this becomes a problem when winching loads slightly down hill or powered load

traveling faster than winching speed.

Banksmen

WINCHING OVER A LONG DURATION.

Overheating of gear box. Breakdown of oil causing eventual failure.Excessive wear, shorter life span, eventual failure.Winch damage or failure. Severe wear and tear.

Rope will try to jump cheek plates.Personal injury or death. Loss of load. Damage to truck.

Stop winch and check for temperature rises.Allow until to cool. After a big job check oil and replace if burnt or has lost

viscosity. Check rope and re-grease.Fit roller fairlead or guide bars.

Winch operator

SIDE PULLING Loads up the winch on an incorrect angle. Winch damage or failure. Severe wear and tear. Rope will try to jump cheek plates.

Fit roller fairlead or guide bars. BanksmenWINCH LOADS BIGGER THAN RECOMMENDED

Winch failure, rope breakage, and severe wear and tear.

Personal injury or death. Loss of load. Damage to truck.

To ease the load on the winch you may find it necessary to utilize a rated snatch block. This effectively halves the speed and halves the stress on the winch.

Winch Operator

SUSPENDED LOADS

Don’t stand under suspended loads

Do not use a winch that is not fitted with a brake to lift loads

Cluttered work area

Serious injury or death may occur.

The load may fall.

Follow all safety procedures and stay well clear of the load, use only certified lifting equipment, make sure winch is fitted with a brake, clean and tidy the work site, take time to overlook the whole procedure, position the lifting point correctly.

Winch Operator


Maintain a clear working space

Rope and equipment failure

Impatience

Laziness

Incorrect positioning of lifting equipment

Task Potential Hazard Consequences Precautions (Controls) ResponsibilityROPE CONSIDERATIONWHILE WINCHING

Rope bird-nests on the drum when rope becomes slack.

Rope jumps over the cheek plates of the drum. Rope over-runs when free-spooling.

Rope can cut into the lower layers of rope on the drum when tension is re-exerted. Rope becomes untidy and twisted on the drum which can damage the rope. Severe damage can be caused to the winch and/or rope. As above.

Fitment of a rope tensioner can alleviate most these problems.

The friction drag brakes may be worn. Replace.

As above.

Banskmen

FOR GENERALMAINTENANCEOVERVIEW

May cause winch failure if proper maintenance procedures are not adhered to

Not adhering to manufacturers maintenance guide

Not reading manual

Not adhering to advice by experienced operators

Impatience

Laziness

Personal injury or death. Winch failure. Loss of load.

Mechanical winch check all drive components for alignment & tighten mounting fixtures. Hydraulically driven check for leaks and proper fluid levels in reservoir & winch etc. Check automatic worm brake and adjust if necessary. Check drum clutch and make any adjustments necessary. Lube all bushes with lithium based chassis lube once a week or every 10 hours of operation. Inspect oil level in gearbox and add as necessary. Check cable for excessive wear. Lubricate the cable based on supplier’s recommendation. Never stand directly in front of the winch while winching. Make sure dog clutch is fully engaged.

Maintenance


operation lift plan... · web viewthis document aims to provide a detailed description of all the...

Documents