Corporate Procedure For Lifting Operations Over Live Process Areas

Corporate Procedure For Lifting Operations Over Live Process Areas
Classification:
Unclassified
BM Code: EP.17.03.05
Issue Purpose
Issue For Use
March 2006
Sakhalin Energy Investment Company LTD.
Corporate Procedure For Lifting Operations
Over Live Process Areas
Doc. No: 0000-S-90-04-P-7073-00-E
Revision: 01
The copyright of this document is vested in Sakhalin Energy Investment Company LTD. All rights
reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval
system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or
otherwise) without the prior written consent of the copyright owner. The contents of this controlled
document shall not be altered without formal approval of the document Custodian.
Corporate Procedure For Lifting Operations Over Live Process Areas
Rev 01
Content:
1.0
INTRODUCTION ............................................................................................................... 4
1.1
1.2
1.3
1.3.1
1.4
PURPOSE ......................................................................................................................... 4
SCOPE ............................................................................................................................. 4
TERMINOLOGY.................................................................................................................. 4
DEFINITIONS ................................................................................................................. 4
USER NOTES.................................................................................................................... 5
2.0
RISKS AND CONTROLS.................................................................................................. 6
3.0
RESPONSIBILITIES .......................................................................................................... 6
4.0
REFERENCES................................................................................................................... 7
5.0
LIFTING OVER LIVE PROCESS AREAS ........................................................................ 8
5.1
5.2
6.0
6.1
6.2
7.0
LIFT PLANNING ................................................................................................................. 8
APPROVAL PROCESS OF LIFTING OPERATIONS OVER LIVE PROCESS AREAS ................... 9
LIFTING EQUIPMENT..................................................................................................... 10
LIFTING APPLIANCES ...................................................................................................... 10
LIFTING ACCESSORIES ................................................................................................... 10
LOAD REQUIREMENTS................................................................................................. 11
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Corporate Procedure For Lifting Operations Over Live Process Areas
1.0
Introduction
1.1
Purpose
Rev 01
Lifting Operations over live process areas should not be considered unless absolutely
necessary and no suitable alternative exists. Methods such as depressurization of pipelines,
shutdown of plant and evacuation of building should be considered.
On occasion however, where lifting over live process areas is considered appropriate, the
control of the lifting operations is of paramount importance for any work site in order to ensure
all operations are conducted safely and in a timely manner but with minimum disruption to
production.
This document details the SEIC requirements for conducting lifting operations over live process
areas. It is compliant with all required Russian Federation Regulations. These are referenced in
section 4.0. It is also in compliance with the SEIC Corporate Standard for Cranes and Lifting
Equipment, and the SEIC Personnel Lifting Standard, also referenced in section 4.
1.2
Scope
This procedure covers the minimum requirements for the administration and control of lifting
operations over live process areas at all SEIC worksites. The procedure also details the
responsibilities of the personnel nominated to control lifting operations at SEIC sites.
Live process areas are defined as, but not limited to, the following for the purposes of this
procedure:
• Areas with live plant or process equipment.
• Buildings occupied by persons.
• Drilling areas including wellbays.
• Sub-sea structures e.g. pipelines, manifolds, caissons etc.…
• Live project pipelines.
This procedure may be applied on a site level to any other areas as deemed fit by the site
management team.
Site Controllers may risk assess a proposed lifting operation and opt to continue without Asset
Manager specific written approval if the severity is 3 or less using the SEIC Risk Assessment
Matrix. Any decision to opt out using this procedure must be suitably documented by the Site
Controller.
1.3
Terminology
Shall – indicates a mandatory course of action.
Should – indicates a preferred course of action.
May – indicates a permitted course of action.
1.3.1 Definitions
The following definitions are used throughout this document.
Competent Person
A Competent Person is adjudged to have sufficient knowledge and experience and relevant RF
certification to assess lifting issues, and the equipment and / or accessories being used.
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Corporate Procedure For Lifting Operations Over Live Process Areas
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Lift Plan
A written document, which will include details of how a lifting operation should be undertaken,
the lifting equipment and lifting accessories to be used, how the equipment and accessories
should be rigged up and the control measures in place to manage the risks identified in the
Risk Assessment.
Lifting Accessory
Any item used to connect a load to a crane or lifting appliance, but which is not in itself capable
of providing any movement to lift or lower the load. Sometimes the lifting accessory is termed
as lifting gear, however within this document, all references shall be to lifting accessory.
Lifting Appliance
Any machine that is able to raise, lower or suspend a load but excluding machines
incorporating a guided load, e.g. elevators, and continuous mechanical handling devices, e.g.
conveyors.
Lifting Equipment
Any appliance, structure or item used to raise, lower, suspend or transport a load. Lifting
Equipment comprises of both Lifting Appliances and Lifting Accessories.
RF
Russian Federation
Rigger
Person competent and qualified to conduct lifting operations with the use of loose lifting
equipment. A rigger shall have the necessary knowledge and qualifications as per
requirements of the RF.
RosTekhNadzor:
Russian Federation regulatory body responsible for ensuring compliance with all relevant
legislation and technical standards for the Russian Federation. Previous body was
GosGorTekhNadzor, which has now been replaced by RosTekhNadzor.
Working Load Limit (WLL)
The maximum load that an item of lifting equipment is designed to raise, lower or suspend. The
WLL does not account for particular service conditions that may affect the final rating of the
equipment.
1.4
User Notes
The requirements of this document are mandatory. Non-compliance must be authorized using
the deviation procedure described in Chapter 10 of the Corporate Document Control Procedure
(000-S-90-01-P-0078-00-E).
A controlled copy of the current version of this document is ONLY available on the SAKHALIN
ENERGY Website and the Global Livelink system. Before making reference to this document,
it is the user’s responsibility to ensure that any hard copy, or electronic copy, is current. For
assistance, contact the Document Custodian.
Users are encouraged to participate in the ongoing improvement of this document by providing
constructive feedback.
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Corporate Procedure For Lifting Operations Over Live Process Areas
2.0
Rev 01
Risks and Controls
The control of lifting over live process areas is of paramount importance for any work site in
order to ensure all operations are conducted safely and in a timely manner and with minimum
disruption to production. To this end, SEIC have chosen to implement this procedure to ensure
that these lifts are carried out in a strictly controlled manner.
This document also specifies the role and responsibilities of the Asset Manager for examining
the implication of risks associated with the lifting operation on an individual asset and overall
business operations basis. No lifting operations over live process areas shall proceed without
the written permission of the Asset Manager.
3.0
Responsibilities
Document Custodian
The Document Custodian is responsible for:
• Providing discipline expertise for the creation, revision (including review of deviations
and challenges in order to make recommendations to the Process Owner) and
retirement of documents relating to the Lifting of Loads over Live process areas to
meet the business needs of the Process Owner in accordance with the Corporate
Document Control Procedure;
• Ensuring the technical validity of this document and that the document has been signed
off to the correct level of technical authority;
• Defining the distribution requirements for this document;
• Keeping a record of user feedback on this document and considering comments at
each document review.
Process Owner
The Process Owner is responsible for:
• Specifying the need for this document and delegates the responsibility for creating it;
• Resolving any practical difficulties encountered in applying this procedure;
• Approving the document prior to issue.
Authoriser
The Authoriser is responsible for:
• The content of this document but in practical terms delegates this responsibility to the
document Custodian;
• Signing off this document at the highest level prior to issue.
Asset/Project Managers, Line Managers and Department Heads
Asset Managers, Project Managers, Site Controllers in ISSOW and Department Heads shall be
responsible for implementing this Procedure by ensuring that activities they control are
managed in accordance with its requirements.
Job Supervisor or Person in Charge (PIC)
The PIC shall be responsible for the safe execution of lifting operations. He shall provide
supervision and maintain overall control of the operation. It is the responsibility of the PIC to
ensure that all relevant documentation and controls are in place prior to the start of lifting
operations over live process areas. The PIC must be fully aware of all hazards involved in the
particular lifting operation as well as all concurrent live process activities. They may appoint a
Competent Person as their deputy to formulate Lift Plans. They are responsible for ensuring
that staff they supervise understand and implement the controls that are identified in this
document.
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Corporate Procedure For Lifting Operations Over Live Process Areas
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Lifting Operations Personnel
Lifting operations personnel are responsible for ensuring that lifting equipment is used and
controlled in accordance with the requirements of this procedure for work they undertake. All
persons involved in the lifting operation shall be competent for the role they fulfill. The
personnel must be involved in the toolbox talk and fully briefed on the particular risks and
hazards associated with the lift and the critical phases of the lifting operation emphasized.
Contractors
Contractors are responsible for ensuring that activities undertaken within the scope of their
contracts are managed in accordance with the requirements of this procedure.
4.0
References
Applicable Regulations and Standards
The procedures and practices contained in this document are compliant with the following
Russian Federation regulations:
RD10-34-93
RD 10-40-93
RD 10-74-94
PB 10-382-00
Standard Manual for Persons Responsible for Safety of Lifting
Standard Manual for Engineering Personnel Responsible for the Safe
Operation of Cranes
Standard Safety Manual for Crane Operators
Regulations on Design and Safe Operation of Cranes
The practices and procedures are also compliant with the following Shell standards:
EP2005-0264-ST
EP2005-0264-GL-01
Lifting and Hoisting HSE
Planning and Execution of Lifting
The practices and procedures are also compliant with the following SEIC Documents:
0000-S-90-04-O-0264-00-E, SEIC Corporate Standard for Cranes And Lifting Equipment
0000-S-90-04-O-0287-00-E, SEIC Personnel Lifting Standard
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Corporate Procedure For Lifting Operations Over Live Process Areas
5.0
Rev 01
Lifting Over Live process areas
Any lifting operation to be carried out over live process areas as defined in the scope. shall be
defined as a Complex Lifting Operation as defined in the SEIC Corporate Standard for Cranes
And Lifting and as such will be subject to strict control measures as defined in that standard.
Prior to considering the lifting of a load over a live process area, the use of an alternative
method or travel path should be investigated.
The key elements, which must be considered in the planning and implementation of the lifting
operation, include the following as a minimum:
•
•
•
•
•
•
5.1
Competency of the lifting operations personnel.
Detailed Method Statement or Lift Plan.
ISSOW PTW Level 2 Risk Assessment.
ISSOW Permit To Work and Lifting Operations Certificate.
Formally recorded Toolbox Talk.
Written Permission of the Asset Manager.
Lift Planning
Method Statement or Lift Plan
A specific Method Statement or Lift Plan shall be generated for each lift over live process
areas. The method statement or lift plan shall cover as a minimum the following:
•
•
•
•
•
•
•
•
Emergency load recovery procedure in the event of loss of crane power.
Identification, setting up and removal, post lift, of all barriers.
Identification of necessary authorizations and approvals.
Designation of lifting and landing sites and load travel route.
Number of personnel required for the operation.
Communication method.
Emergency shut down / evacuation procedures for the live area in the event of
problems developing with the lifting operation.
10 Questions for a Safe Lift.
The method statement or lift plan shall be drawn up and reviewed by suitably competent
persons following the Lift Planning Flowchart in the SEIC Corporate Standard For Cranes And
Lifting.
Risk Assessment
An ISSOW defined Level 2 Risk Assessment following the SEIC Corporate Standard For
Cranes & Lifting, Section 7.3, shall be generated for each lifting operation over live process
areas. Each risk identified shall be assessed using the Risk Assessment Matrix (Appendix 1 of
the Standard). The lift planning process shall reduce all risks to as low as reasonably
practicable before the lifting operation may commence.
The Risk Assessment must cover as a minimum the areas identified within the SEIC Corporate
Standard for Cranes & Lifting section 7.3 with particular emphasis on the following:
• Implications of loss of crane power or loss of load over live area.
• Breakdown of communication method.
• Proximity hazards.
• Management of concurrent conflicting operations.
• Barriering off of lifting operation area and control of access to non-involved personnel.
• Management of changes to lift plan or method statement.
• Implications of potential dropped objects over live process area.
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Corporate Procedure For Lifting Operations Over Live Process Areas
5.2
Rev 01
Approval Process Of Lifting Operations Over Live Process Areas
Lifting Operations Certificate (LOC)
A Lifting Operations Certificate shall be created for each lifting operation over a live process
area. The validity period of the LOC shall be 7 days maximum.
Permit to Work
A Permit to Work shall be raised for all lifting operations involving lifting over live process areas.
The Permit To Work with the associated Lifting Operations Certificate will satisfy the
requirement for Site Manager (Site Controller) approval for the lifting operation to proceed.
Asset Manager
The Asset Manager must issue written permission to the Site Manager for the acceptance of a
requirement for lifting over live process areas. It is the responsibility of the Asset Manager to
consider the implications of the risks involved in the lifting operation on both the individual asset
and related assets. The written permission to proceed issued by the Asset Manager shall
specify if a further Readiness Review is required by the Asset Manager at the point of Permit To
Work Approval.
Site Manager
The Site Manager will fulfill the responsibilities and function of the Site Controller within the
ISSOW system. The Site Manager is responsible for designating a suitably competent and
qualified Job Supervisor (PIC) for the lifting operation. Lifts over live process areas are
designated as Complex Lifting Operations and therefore require the Site Manager approval in
the form of the Permit To Work and Lifting Operations Certificate issuing.
Note: the Site Manager may only approve the execution of the lifting operation if the written
permission of the Asset Manager has been obtained.
Lifting Operations Assessor (LOA)
A competent Lifting Operations Assessor must assess all complex lifting operations. The Lifting
Operations Assessor may be the Job Supervisor or Person In Charge if they have the
necessary knowledge and experience. The Lifting Operations Assessor will determine if there is
a requirement for the Lift Plan to be subject to a further review by a designated Lifting Technical
Authority.
Lifting Technical Authority (LTA)
A Lifting Technical Authority is defined as a competent person with the responsibility of
providing guidance on the acceptability of lifting arrangements. If the basic nature of the lifting
operation would not normally demand a Complex categorisation if not being conducted over a
live process area then it is unlikely that the approval of a Lifting Technical Authority would be
required.
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Corporate Procedure For Lifting Operations Over Live Process Areas
Rev 01
Asset Manager (AM) Issues Written Permission To Perform Lifting
Operation
On Completion of Business Impact Risk Assessment. Define Require ment for
Readiness Review.
Create Level 2 risk
assessment, Lift Plan / Method
Statement
LOA Review &
Authorise
LTA Review
Required?
No
Yes
AM Review
& Approval
Yes
LTA Review
& Approval
AM
Readiness Review
Required?
No
SC Approval Via PTW
& LOC Issue
Perform Lifting Operation in
accordance with Lift Plan /
Method Statement
Approval Process For Lifting Operations Over Live Process Areas
6.0
Lifting Equipment
All lifting equipment used must be fully compliant with the requirements of the SEIC Standard
for Cranes and Lifting Equipment.
6.1
Lifting Appliances
The lifting appliance shall meet the requirements for lifting appliances stated in the SEIC
Corporate Standard For Cranes and Lifting the lifting appliance and must be fitted with suitable
systems to allow emergency recovery of the load in the event of loss of primary power to the
appliance.
6.2
Lifting Accessories
All lifting accessories shall meet the requirements of the SEIC Corporate Standard For Cranes
and Lifting for design, manufacture and inspection.
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Corporate Procedure For Lifting Operations Over Live Process Areas
7.0
Rev 01
Load Requirements
Extra precautions shall be taken to ensure the stability of the load and ensure the load is free of
potential dropped objects.
If necessary, taglines may be used to assist in the correct orientation of the load however the
use of taglines must be assessed to ensure snagging will not occur during movement of the
load.
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