LIFT PLANNING

Introduction

Competent lift planning, which includes Level 1 or Level 2 risk assessment, is fundamental to safe lifting
operations. It has been shown that inadequate or insufficient lift planning, along with poor supervision
and hazard awareness, is a major root cause of lifting related incidents.

With this in mind it is unsurprising that internationally, it is a regulatory requirement that all lifting
operations “must be planned by a competent person”. But perhaps more accurate, would be to state
that all lifting operations “must be competently planned”.

Lift plans shall be developed by a competent person along with input from those involved in the
operation, before approval, endorsement and authorisation.

The primary considerations when planning or executing lifting operations are…

 How the lifting operation is to be performed

 The identification and mitigation of hazards
 The Safe System of Work to be used, including the identification of…
 The necessary equipment
 Personnel
 Resources
 Controls and actions

Lift plans shall also consider the deck or ground strength required to carry out the operation safely.

Most day-to-day lifts will indeed be planned by a single competent person but depending on the
complexity of the lifting operation and / or the magnitude of the lift, the planning will probably involve
the input from a lot more than one competent person, for example for a heavy offshore lift between a
floating crane, a lay barge and a fixed installation, there may well be input from…

 The Installation Manager

 The Crane Barge Master
 The Master of the vessel towing the lay barge
 Project Engineers
 The Construction Supervisor
 The Rigging Foreman
 A Lifting Specialist or Technical Authority
 The Barge Crane Operator, and in certain circumstances…
 A Meteorologist

These people all have their own competencies in different areas, but which may not just be relevant but
actually crucial to the safety of the overall lifting operation.

Many factors have to be considered with regards to reducing risks during the transportation and
placement of a load on site. Lift planners and / or project teams need to consider all the hazards and
risks, and where possible design them out. Any risks that cannot be designed out must be considered
and communicated throughout the planning and construction phases and applied to the task specific
Job Safety Analysis and risk assessment.

With this in mind the purpose of this awareness course is to highlight the many factors that must be
considered when planning a lifting operation.

Contents

During this course the slides will stop periodically, at which point you will be required to answer a series
of questions to confirm understanding. The questions must be answered correctly before you can
proceed to the next section. As a result, at the end of the course, you will have met the course objective
of acquiring a demonstrable level of knowledge and understanding of the following subjects…

 Regulations
 Categorization of Lifting Operations
 Lift Planning
 The Load
 Lifting and Landing Sites
 Route to be Travelled
 Environmental Factors
 How you are going to lift it?
 How many people will be involved?
 How will everyone communicate?
 Step-by-step Procedure
 Diagrams or Sketches
 Rigging / Material Lists
 Approval, Authorisation and Endorsement
 Management of Change, Lessons Learned, and…
 A Safe Approach to Lifting

Before moving onto the next section, we would advise that you have a pen and paper ready to take
notes as you progress through the course. This will assist you when you are required to answer the
questions at the end of each section.

Regulations

In the US there are very few specific requirements regarding the need for lift planning.

For example, in API RP 2D it is not mentioned in the main body of the document, but does state in
appendix A3 for Rigger training, that training in lift planning is required. However, this may change in
future editions.

Another US example is 1926.1432, Multiple crane / derrick lifts, supplemental requirements; it states in
plan development…
…Before beginning a crane / derrick operation in which more than one crane / derrick will be supporting
the load, the operation must be planned.

Whereas, in Norway and the UK there are specific requirements for the planning of lifting operations,
competently.

For example, in Norway, NORSOK Standard R003, the Safe Use of Lifting equipment, and R005 the Safe
use of lifting and transport equipment in onshore petroleum plants, both state…

…Each lifting operation shall be planned in order to ensure safe execution and that all predictable risks
are taken into consideration. The planning shall also be carried out by personnel who have the relevant
competence.

In the UK, regulation 8 of the Lifting Operations and Lifting Equipment Regulations specifies that every
lifting operation must be properly planned by a competent person, appropriately supervised and carried
out in a safe manner.

It is also indicated in LOLER’s Approved Code of Practice that the level of planning and risk assessment
increases with the complexity of the lifting operation, as does the required level of supervision.

The result of a lifting-related incident is almost always very costly, in terms of damaged equipment and
plant, subsequent delays to the job, the costs of an investigation, but more importantly, the costs,
financial and otherwise, to the people who are hurt or killed by the accident. 

For these reasons, lifting operations, whether carried out offshore, onshore or onboard a vessel must be
strictly controlled to make sure that the personnel doing the work have the requisite amount of
knowledge and experience to carry out the work safely.

Categorization of Lifting Operations

To ensure that lifting plans are developed consistently all lifting operations must to be categorised as
either category 1, 2 or 3 and shall dictate the required level of…

 Risk assessment
 Lift planning
 Training and competence
 Approval and authorisation
 Endorsement, and…
 Peer review when required

Categorisation is completed by using the applicable flowcharts, which are specific to the environment
where the lift will be performed. The environments are…

 Onshore
 Offshore
  Marine, and…
 Subsea

These flow charts contain a list of questions, columns for answers and category areas, which are aligned
to specific questions. Starting at the top and working down, the user answers, either ‘yes’ or ‘no’ to the
questions.

The first question that is answered ‘yes’ identifies the category of lift by aligning with a defined area and
therefore no need to answer any further questions. For example, the onshore categorisation flow chart
asks some of the following questions, which are aligned to category 3…

 Does the lift need a heavy lift crane to be built on site?

 Is the mobile crane percentage of utilisation above 80 percent?
 Does the lift involve personnel lifting? or…
 Does the lift have limited boom clearance i.e. less than 1metre or 3.3 feet?

If you answered ‘yes’ to the second question, then it would be a category 3 lift. If however, you
answered ‘no’ to all the category 3 questions, you would then keep going and answer the category 2
questions, and so on, until you either answered ‘yes’ to a question or until all the questions were
answered with a ‘no’.

Personnel should also refer to the Lift Management Flow Chart for further guidance.

These lifts can be categorised as Category 1, if they meet the following criteria…

 A formal rig-site lifting competence assessment program is implemented and approved by the
Global Wells Organisation Lifting Technical Authority
 The lifting plan has been authorised by the Site Lifting Co-ordinator as Category 1
 A risk assessment that recognises that the lift shall be carried out by the drill and well service
crew has been developed and approved
 The drilling and well service crew have the necessary experience and are assessed as competent
to perform this category of lift
 The lift is for drilling and well operations and not for the maintenance of associated drill floor or
well operations equipment
 The lift is on or above the rig floor / pipe deck or other drilling areas
 The Site Lifting Co-Ordinator has agreed that the drill crew can execute the lift
 One person is appointed in charge and in control of the lifting operation, and…
 The senior tool pusher / well site leader (or their delegate) maintains a register of persons
competent to supervise lifting operations in drilling areas

If lift fails to meet these criteria, then it must be categorized as per the standard categorization process.

It should also be noted that the use of permanently installed drilling equipment, such as the draw works,
bridge racker and iron roughneck for example are already covered in existing drilling documents and are
therefore excluded from the Management of Lifting Operations and Lifting Equipment UDP.

Section 2
Lift Planning

Lifting plans have essentially three main sections; a rigging / materials list, a method statement and a
sketch or drawing, which is optional depending on the complexity of the lift. These sections are where
the majority of information is recorded.

The detail in the method statement and material list is also dictated by the complexity of the lift, for
example category 1 or routine lift plans may only have one page, whereas category 3 or complex lift
plans may have several pages.

Also included in standard planning documents should be sections for recording…

 A brief description of the lifting operation

 The weight of the load, the rigging and the center of gravity location
 Level of supervision and, roles and responsibilities
 Site name or location of the lift
 The category of lift
 A tick box section for possible considerations. Any item highlighted in this section should be
addressed in more detail later in the plan. For example, if the box related to tag lines was
highlighted, then how many are to be used, where they are connected, etc. should be detailed
in the method statement and / or material list
 Details regarding the route to be travelled, and…
 Specific details related to who produced the plan, who approved, authorized or endorsed it,
associated document numbers, identification number, etc.

To start with a lift plan should begin with a brief description of the lifting operation, which should detail
for example the following points…

 What you are lifting in other words a description of the load?

 How heavy is it, what is the weight of the rigging and where is the centre of gravity?
 Where you are lifting it from?
 Where you are lifting it to?
 How you are going to lift it?
 How many people will be involved, what are their roles and responsibilities, and…
 How will everyone communicate?

This initial outline is the start of the planning process. Each point can then be considered, and then the
relevant information entered into the lifting plan.

The Load

We will first look at the load. Consideration must be given to…

 Is it high value or relatively unique, in other words costly to replace, and…

 Is it critical to operations, in other words will delay or failure of the lifting operation result in loss
of production
In addition…

 Where is the centre of gravity located? This must be known so that reaction forces, sling
tensions, stability, etc. can be determined
 
 Structural integrity; is it rigid or flexible, is it capable of withstanding the forces to be applied?
 Is there a risk of dropped objects
 It’s size and shape, with regards to clearances during the lift, travel and landing
 What’s inside? Does it contain a fluid, is there residual material, will it affect stability, etc?
 Will it have to be slung, does the load need protecting from the slings, do the slings need
protection from the load, or…
 Does it have dedicated lifting points?

If lifting points are fitted, they need to be designed dimensionally to correspond with a shackle or other
type of connecting equipment and with an applicable capacity. The following points also need to be
considered regarding lifting points…

 Design and manufacture

 Impact factors or dynamic amplification factors with regards to the lift environment, for
example when working offshore, marine or subsea
 Sling angle tension
 The availability of connecting equipment
 Lift point orientation / alignment with applied forces
 Whether the lift is statically determinate or indeterminate
 The anticipated number of operations during its life cycle, and…
 Specific test and inspection requirements

Finally, but probably the first question asked about the load is, what does it weigh?

The weight of the load will determine the size of the rigging and will influence your choice of lifting
appliance and its capacity. Therefore, you must first find out the weight of the load from a accurate
source, for example from the manufacturers documentation, a data plate attached to the load, a
shipping manifest, calculation, etc. and then it should be verified or confirmed from another source.
If these are not available and only an estimate can be made, then it is essential that a reserve or
contingency factor is added to the estimation, such as 25 percent.

There are also other circumstances, such as in the marine environment where dynamic loadings are
anticipated, where a weight factor, contingency or reserve is also required. This would be calculated by
multiplying the gross weight of the load by the reserve or contingency factor.

Adequate contingencies, relative to the lift environment must be considered and included during the lift
design stage to ensure that the load, lifting equipment and site conditions are capable of safely
maintaining the anticipated loadings.

When confirming the weight of a load the equipment would normally be a calibrated load cell
suspended from a crane but in the case of heavier loads such as offshore modules, these can be
weighed by using a set of calibrated hydraulic rams or jacks.  This is usually the most cost-effective way
of weighing a heavy load.  Using this set up will also allow you to confirm the centre of gravity in the
horizontal plane.

There are also subsea considerations, regarding the load, such as…

 Hydrodynamic loadings and seabed suction

 Water depth
 Resonance effect, for example in ultra deep water
 Load integrity with regards to water pressure
 Changes to the in-air load weight due to the effects of flooding, draining, marine growth, debris
and grout, if removing from an existing subsea structure or asset, and…
 Changes to buoyancy and the centre of buoyancy

To finish this section, always remember to allow for the additional weight of the rigging and when
applicable the crane hook block when selecting the lifting appliance.

Lifting and Landing Sites

Next you will need to consider where the load is located and where you are lifting it to.

For lifting and landing, consideration must be given to…

 Is it clear to be lifted and landed or is the load in a tight space?

 
 Can it be lifted and landed without being damaged or damaging surrounding plant or
equipment?
 
 What are the safe areas and exclusion zones?
 Is the landing area capacity sufficient?
 Is there a pre-landing hold off position if lifting subsea?
 What are the acceptable sea state conditions during vessel loading and offloading operations?
 If lifting from a vessel what are the acceptable motion limits, are there DP limitations and is
there heave compensation criteria?
 Are there any height restrictions, and…
 
 Does the angle of the crane boom give adequate clearance to the load and structures when
elevated?

If the load has to be stacked, then this shall only be permitted…

 After a full risk assessment has been completed

 After written approval by the Site Manager and the Lifting Technical Authority has been given
 If the load is specifically designed for that purpose and is clearly marked as suitable for stacking
 If the load is designed not to cause a snagging hazard
 If stacking is confined to a pre-designated stacking area, and…
 There is the facility to attach and detach the sling assembly at ground level
Sometimes, once a load is lifted, for various reasons it cannot be re-landed until it reaches its final lay-
down point; this is called a non-returnable load. 

This can exacerbate any problems encountered during the lifting operation especially if you are working
within a weather window.  If a load cannot be re-landed, a more in-depth level of planning is required
and increased safety factors or contingencies applied to the lifting accessories and appliances.

Section 3

Route to be Travelled

Whether you are just moving a load or travelling with the load, for example using a crawler crane or Self
Propelled Modular Transporter, you need to inspect the route to be travelled (as long as you are not
lifting over water) as this will help identify any obstacles such as power lines, underground services,
height restrictions, clearances between existing pieces of plant and equipment and the actual ground
conditions. 

If the route takes you close to high voltage electricity cables it is advisable to call the power company to
see if the power can be switched off for the duration of the lifting operation. Specific allowable distances
from the power lines change depending where you are in the world so they should be verified during
the planning stage.

On a busy worksite, you can also take this opportunity to cordon off the area to primarily prevent non-
involved personnel inadvertently walking under or near to a suspended load but also to keep personnel
away from drop and equipment tipping zones.

When lifting subsea the route may not be directly below the crane tip, currents and tides may drift the
crane wire and load away from the vessel. The depth of water must also be considered.

If you are lifting between a vessel and an installation offshore, remember to consider the additional
forces created due to the dynamics. In addition, be aware of the drop cone criteria if lifting over or near
subsea process equipment.

This brings us onto lifting over or in close proximity to live plant, which is defined as any lifting operation
where there is a process safety risk of the load, lifting appliances and / or lifting accessories impacting,
damaging and / or rupturing live plant. 

Live plant is defined as equipment containing hazardous, pressurised, energised or strategic resource.
Examples include: pipes, electrical cables or vessels containing hydrocarbons. It also includes primary
power generation units, for example turbines and their exhaust systems.

Lifting over or in close proximity to live plant, regardless of lift category shall not be undertaken unless…

 No other feasible alternative exists

 Risks are reduced to as low as reasonably practicable, and…
 An operational contingency plan is in place
Operational contingency plans shall define the potential worst-case consequences in the event of a
dropped object or catastrophic failure of the lifting equipment, documenting the mitigation measures to
be taken prior to the lift and the emergency response actions required in such an event.
Exclusion zones used during the lift shall be extended to match the requirements of the operational
contingency plan.

In addition, these plans should only be reused for repeat operations, where the original operation lift
plan, equipment, assumptions made and operating conditions are verified as unchanged.

During the planning stage for the route to be travelled, details, if applicable, should also be recorded on
how hands-free lifting and the safe use of taglines will be accomplished.

Finally, on this subject, if you are transporting a load, you must consider stability. Centre of gravity
height, ground conditions, incline angle, etc. must all be assessed. You certainly do not want to follow a
successful lift with the load falling off or overturning the transport.

Environmental Factors

After assessing the lift and landing locations and the route to be travelled the following factors need to
be considered with regards to the environmental conditions during the lift, which are for example…

 The time required to perform the lift

 The weather forecast
 Visibility, available daylight and the availability of artificial lighting
 Wind speeds, sea states, tidal patterns and currents

For example, a crane boom can act as a conductor and attract a lightning strike during a thunderstorm.
Therefore, if there are clear signs of an approaching thunderstorm, lifting operations must cease and all
personnel should be moved out of the vicinity of the crane, until the possibility of danger passes.

In addition, wind can exert additional forces to the crane and the load, which can affect both the
strength and stability of the crane and safe handling of the load.  It is therefore essential that the
maximum wind speed at which the crane must be taken out of service is recorded on the lift plan.

How you are going to lift it?

We will now look at the criteria to consider regarding the lifting appliances and the rigging. After first
asking how much the load weighs, this is probably the most common second question; that is ‘how are
we going to lift it?

To start with, all equipment must be used within its rated capacity and never purposely overloaded. It
must also only be used for the purpose for which it was designed, such as fitted with the correct
counterweight, the correct outrigger configuration to be used, supplied with suitable instructions, load
charts, etc.

In addition…
  If a crane is to be used, can it operate within it’s safe operating radius, which should be based on
the worst-case radius
 Is the appliance within the acceptable capacity utilisation percentage, such as 80% or under
 If using more than one crane, you will need to consider their relative lifting positions, capacities
and operational speeds
 If you are using crawler cranes, have you considered their relative travelling speeds?
 
 If using multiple air hoists or manual hoists, are the hoisting speeds compatible and what is the
acceptable working angle, for example during cross hauling operations?
 
 Have you considered how to control the level of the load and hence the loading in each hoist?
and…
 Will extreme heat or cold affect the capacity of the equipment?

Next, whether just lifting, slewing and landing the load using a mobile crane or travelling with the load
using a crawler crane or transporter, the ground has to adequately withstand the intended loadings.
Therefore, the overall gross weight to be applied, the maximum allowable ground bearing pressure
calculations and load spreading details must be supplied.

If the crane has to work anywhere near an excavation, remember that the outrigger / track load enters
the supporting surface at 45 degrees so it’s imperative that the outrigger / track is positioned no closer
to the edge of the excavation than a distance slightly greater than the depth of the excavation. The
location of any underground services such as sewers, utility supplies, etc. must also be verified.

Remember also that the ground conditions can change with the weather, and that it’s load-bearing
capacity can be reduced especially when it rains.

There is also criteria specific to the rigging or lifting accessories that need to be considered, for example
the…

 Availability of suitable rigging

 Compatibility of the various rigging components with each other
 Weight of rigging items with regards to gross weight to be lifted and manual handling
 Protection of rigging from the load, for example sharp corners
 Wire rope bend radii and efficiencies
 Increased stresses in the rigging due to angular loading and dynamic factors

In this section we will also cover specific considerations with regards to uncertified steelwork and lifting
points, Self Propelled Modular Transporters (SPMTs), marine and / or subsea lifts and lifting personnel.

If the use of uncertified steelwork and lifting points is required, then they shall only be used after
assessment and their use approved by a Structural Technical Authority.  If used repeatedly or
periodically then they must be…

 Assessed
 Examined
  Overload tested
 Certified, colour coded, and…
 Marked with a SWL or WLL and unique identification mark

SPMTs have the ability to lift and lower loads and as such their use must be planned. However, there is
specific information when using this type of equipment that must be considered and contained in the lift
plan, this includes for example…

 As-loaded drawings
 Stability calculations, which should be based on a three-point suspension grouping with a
minimum, non-combined centre of gravity and stability angle of nine degrees. Where nine
degrees is not achievable a combined centre of gravity should be used and a physical connection
made between the load and the trailer
 Route survey, swept path analysis, and…
 Lashing calculations

This type of lift is a category 3 operation, with the lift plan being sufficient to demonstrate that the load
can be safely transported through to the point of installation at site. In addition, all SPMTs should use a
simple level gauge in addition to the contractors’ monitoring system.

In addition to the previous considerations all marine and / or subsea lift plans should consider the
following…

 The safe use of airlift bags

 Equipment relative to ease of use by divers and ROV
 Equipment and load identification in poor visibility conditions
 Aluminium ferrules shall not be used for subsea lifts without approval of the BP Lifting Technical
Authority
 The Crane Operator shall be assessed as competent to carry out subsea crane operations
 Pre-planning of subsea lifting operations shall consider the safety of divers, ROV and the
integrity of subsea installations or equipment
 Safety factors, for example skew load factors, sling, shackle and grommet safety factors, etc.
 Bumper and guide details
 Load stability
 The interface between floating lifting appliances and fixed structures
 Critical clearances
 Communication protocols, and…
 Hazardous material

Remember, subsea lifts are a specialised form of lifting and therefore the design of which should only be
undertaken by qualified engineers with experience in this area.

When the lifting of personnel is required, whether with cranes, forklifts or winches and regardless of lift
environment they shall also be considered as a high-risk operation and be categorised as a category 3
lift.

This type of lift operation shall also only be used when it is…
  Not practicable to gain access by a less hazardous means
 Fully managed in accordance with strict procedures, and…
 Rigorously risk assessed to ensure that the risk of personnel falling from a carrier, being crushed,
trapped or struck while being transported in a carrier has been mitigated to as low as reasonably
practicable

In addition…

 Lifting Technical Authorities need to monitor and record the quantity and type of personnel
lifting operations performed at each facility
 Lifting equipment for lifting personnel shall be thoroughly examined for the purposes of
recertification at least every six months
 Site Lifting Coordinators need to consult Site Managers before approving any lift plan, which
involves the lifting of personnel
 Only carried out with lifting equipment, which has been specifically designed for lifting
personnel, certified for lifting personnel, and…
 A rescue plan is developed, made readily available and effectively communicated

SECTION 4

How many people will be involved?

A lift plan should clearly identify the number of personnel required to

carry out the lift, along with their roles and responsibilities.

In addition, when you list the personnel required to perform the lifting
operation, for example Riggers, Banksmen, Slingers, Crane
Operators, etc. remember to verify their qualifications and experience
levels.

Normally, there would be a minimum of three people involved in a

simple lifting operation involving a crane, however if the load is
travelling a substantial height or distance, you may require more than
one Banksman to guide the Crane Operator. You may also, if you are
multi-point lifting with chain blocks, need more to operate the hoists. 

In addition, depending on the size of the load and where it is being

landed, you may also require several load-handlers on tag lines.
Controlling all these people as the lifting operation progresses is not
easy and so it is imperative that you establish proper communications
prior to the start of the lift, which we will cover in the next section.

How will everyone communicate?

The methods of communication must be clearly addressed and

agreed during the risk assessment and planning stages along with
being defined and communicated during the pre-lift safety meeting.

The basic form of communication in routine and simple lifting

operations is hand-signals.  These are acceptable for the majority of
lifts in good light conditions but for safety reasons, it is better if these
are backed up with short-wave radio communications as well. 

However, when multiple lifting or cross-hauling equipment is being

used, radios are a must.  If this is the case then the various cranes,
hoist or winch operators and other participants must all be given
simple but distinctive call signs such as Crane 1 and Crane 2, winch A
and winch B or tagline 1, tagline 2, etc. to reduce the chance of a
communications error.

In addition, lifts, which may be passing from a vessel to the quayside

or from a barge to an installation, the lift controller or person in charge
will probably change as the lift progresses, therefore responsibilities
will also change, which will need to be communicated effectively to all
concerned.

There must also be a clear communication process indicated in the lift

plan between the lift team and facility management and a plan for
unexpected events or change, for example a general alarm could be
sounded if an incident occurs.

Step-by-step Procedure

At the planning stage, the competent person or team doing the

planning will gradually build up a picture of the lifting operation and will
be aware of what has to be done and in what order to achieve a
successful and safe lift.
This information will have to be relayed to a team of lift personnel who
are actually doing the physical work and the best way to do this is
through a written step-by-step procedure.  When putting this together,
you should imagine yourself actually doing the job and write down in
the correct order the sequence of events.

This will help identify any possible problems and allow you to deal with
them at the planning stage rather than have them crop up during the
actual lifting operation, for example you may rearrange the order of
events to increase efficiency.

The step-by-step procedure allows you to transmit specific information

to each and every member of the lifting team to reduce as far as
possible, the chance of people making mistakes.

It should start, for example, with instructions to hold a pre-job safety

meeting, inspection of the work area and equipment, followed by
cordoning off the work area. It should then finish with personnel tidying
up the worksite, inspecting equipment and signing off the job as
complete. 

If written correctly with all the relevant information, each and every
person involved will know exactly what they are supposed to be
doing.  They will know what equipment goes where, when to operate
it, they will be aware of any specific hazards and will know where to
position themselves to reduce the risk of injury in the event of things
going wrong.

The step-by-step procedure can also be used as a template for the

risk assessment and should also be the focal point of the pre-job
safety meeting before the lifting operation commences.

Diagrams or Sketches

A diagram or sketch of the overall lifting operation showing where the

load is travelling from and to is invaluable to the team doing the work. 
During production it can also help identify obstructions, headroom
problems, clearance problems etc. and it is better to identify these at
the planning stage than discover them when you are actually doing
the job.

However, a diagram, sketch or drawing should never be used in

isolation. The method statement must always be studied in detail.

For more complex lifting operations, such as subsea lifting operations,

there may be an additional series of sketches, for example showing
the rigging arrangements at the various lift points.  These are also
useful for showing how the rigging should be installed by giving a
visual picture.

Once again, the process of making up these sketches, if done to

scale, helps identify if there are any dimensional compatibility
problems between the various components.  These diagrams and
sketches can also be cross-referenced with “hold” points that refer to
additional instructions and / or safety warnings.

In addition to the above considerations, all onshore crane lift plan

drawings should be drawn to scale and detail for example…

 Crane Model

 Crane counterweight to be used

 Outrigger configuration, position and load spreading details

 Tail clearance at slew path

 Crane location and set up dimensions

 Proximity of underground services

 Load, rigging, hook block and total weight

 Worst-case radius and capacity

 Percentage of capacity utilisation

  Pick up, set down locations, direction and path of slew

 Headroom limitations

 Boom length and clearances

 Height of load at worst case

If sketches exist for a lifting operation from a previous time, they must
be reviewed to ensure there have been no changes which could affect
the efficiency / safety of the lift.

Rigging / Material Lists

Once you have created your diagram / sketches of the lifting operation
and prepared the step-by-step procedure, you will have to put together
a rigging and materials list. 

However, before we move onto the list, we must ensure the

equipment we use is fit for purpose. Therefore…

All lifting equipment needs to be of adequate strength and stability for

each load, having regard in particular to the stresses induced at its
mounting or fixing point. In addition, every part of a load and anything
attached to it and used in lifting it is of adequate strength.

Equipment to be used should have been procured to recognized

standards, adequately constructed, certified and suitable for its
intended task.

In addition, lifting equipment has also to be supplied with appropriate

certification and be clearly marked with…

 A Safe Working Load (SWL) or Working Load limit (WLL), which

includes the SWL / WLL for each configuration

 A unique identification mark to allow for traceability to it’s

certification, and…
  ‘Suitable for lifting personnel’ if designed for lifting personnel

Furthermore, to increase operational safety factors lift planners and

project teams, during the initial design stage, should principally
consider an 80% or below utilisation of a crane’s capacity.

However, if you intend crane utilisation to be above 80%, then review

and acceptance of the proposed utilisation by a Technical Authority
should be sought.

Getting back to the list, it should contain all the rigging equipment
required to do the lift, for example cranes, hoists, winches, slings,
shackles, etc.  You must be accurate with the descriptions to make
sure you get the correct materials. 

Remember to include such things as safe working loads or capacities,

required operating radii (for cranes), sling lengths and angles, heights
of lift for hoists, rigging screw diameters, thread type if using hoist
rings, eyebolts or eyenuts, torque settings, etc.

Bear in mind that your procurement department may hire in some of

the larger lifting appliances so in cases where you have selected
specific manufacturer’s models because of their dimensional suitability
/ compatibility, make notes on the rigging material list that they must
NOT deviate from the stated specification.

If using rigging screws in a lifting scenario, remember that they are

quite often supplied uncertified as they are looked upon as “tie-down”
or lashing items.  Always insist that they are load-tested and certified
for lifting.

When detailing endless slings, be very specific when describing the

length, for example you can order them by circumference, which is the
total length of the round sling (measured around the circumference) or
by the effective working length, which is the linear length.

If you are ordering various slings of similar but slightly different

lengths, have the manufacturers hard stamp the lengths on the
ferrules at the time of manufacture.  This can save a lot of time in
sorting through them when delivered, especially if they are large /
extremely long or heavy slings.

By the same token, if asking for multi-leg slings with varying leg-
lengths, for example to suit a load with an off-set centre of gravity, get
the rigging shop to mark up the legs accordingly so you know which
leg gets attached to which pad eye on the load.

Include access equipment such as ladders or cherry-pickers that may

be required to help with the installation of the hoists and rigging.

Finally, don’t forget the peripherals such as barrier tape, specialised

PPE if required, packing materials for protecting the rigging, level
gauges, etc.
SECTION 5

Approval, Authorisation and Endorsement

All personnel who approve, authorise, endorse and peer review lifting
plans shall have a defined level of competence in compliance with
local OMS procedures.

The first step in this process is approval and all category 1, 2 and 3 lift
plans shall be approved by a Site Competent Person.

Approval signifies that a lifting plan is safe to execute, it mitigates all

risks and hazards, provides a safe system of work and is in
accordance with Local OMS requirements and regional legislation.

Next is authorisation; all category 2 and 3 lift plans shall be authorised

by a Site Lifting Co-ordinator.

Category 1 Lifts shall be audited by the Site Lifting Co-ordinator

periodically to confirm conformance with local OMS requirements.

Authorisation signifies that the lift has been correctly categorized,

that the lifting plan has been developed correctly and that the correct
management processes have been followed during the applicable
approval and endorsement stages. In addition, adequately considered
and mitigated all personnel safety and process safety risks.

All Category 3 plans shall be endorsed by either a competent delegate

who is independent from the lifting contractor.

Endorsement signifies that a lifting plan is safe to execute, it

mitigates all risks and hazards, provides a safe system of work and is
in accordance with Local OMS requirements and regional legislation.
In addition, that all required technical support has been provided and
incorporated.

Peer Review, when required, signifies a high-level assurance as part

of the endorsement stage. It has been designed to provide an
independent view of high-risk lifting operations.

Where site-based personnel have not achieved the required level,

then duty will be escalated to a suitably competent person nominated
by the Technical Authority as appropriate. Under no circumstances
should a lift be conducted without the correct approval, authorisation
or endorsement.

Management of Change and Lessons Learned

It is worth mentioning at this stage of the course that when a lifting

operation, for whatever reason, deviates from the approved /
authorised lift plan and / or additional hazards are identified, the task
must be stopped, made safe immediately and all personnel moved to
a safe position.

Many injuries, and some fatalities, have resulted from not following
this approach. Therefore, the purpose of this section is to instruct
personnel that anyone can “stop-the-job” when there is a deviation or
where they suspect that safety has or is about to be compromised. In
addition, once the job has been stopped, that there is a process that
should be followed, which is management of change. This process
provides a route for personnel to follow, which is designed to ensure
that changes are managed safely and efficiently.

Any member of the lifting team can request a management of change

to be invoked and suspend the activity, if for example there is a…

 Deviation from company procedures or the lift plan

 Modifications to equipment

 Change to the equipment set up and / or the sequence of events

 Requirement for additional equipment that is not included in the

lift plan, and…

 Significant change to environmental conditions

The effectiveness of the management of change process is dependent

on an individual’s ability to identify that safety has, or is about to be,
compromised. Therefore, it is essential that personnel who are
required to plan and carry out lifting operations have a suitable level of
hazard awareness, work experience and task knowledge, in other
words, competence.

In addition, to prevent or reduce the risk of incidents happening, there

must be a system of post lifting operation learning in place.

Everyone involved in the operation should have the opportunity to

discuss and record applicable improvements on the lift plan. Any
learning points recorded on the lift plan should be reviewed by the Site
Lifting Co-ordinator and where appropriate, actions taken and
communicated to all relevant personnel.

In addition, any significant lifting related incidents and accidents shall

be reported to the Lifting Technical Authority allowing the community
of practice to be briefed and hence preventing re-occurrence.

A Safe Approach to Lifting

This last section offers guidance for effecting safe lifting operations.

Competence

Any person using lifting equipment must be trained to operate that

equipment.  The person must also have a working knowledge of its
capabilities and the defects likely to arise in service.  Therefore,
always verify the competence of personnel when planning a lift.

Never Exceed the Safe Working Load

During the planning stage, ensure that the load imposed on any item
of equipment or on part of any item does not exceed the equipment’s
safe working load.  When there is any uncertainty about the weight of
the load or the load likely to be applied to a particular part of the
equipment, it is recommended that load-sensing devices be used.  In
addition to the above, care should be taken to ensure that at all stages
of the lift, the load remains in a stable condition.

Correct Use

The equipment should be used only for the specific purpose for which
it is designed and should not be adapted for any other purposes
without the approval of a Technical Authority.

Check The Lift

Plan to carry out trial lifts.  This allows the operator to check his
estimations of balance, stability, and general security of the load while
it is in a relatively safe position.  If any discrepancies are found the
load should be lowered and the slinging revised.  The sequence of
trial lift and adjustment should be repeated until the operator is
satisfied that the load is balanced, stable and secure.

Think Ahead

Plan the route the load will be travelling on the way to the lay-down
point and ensure any obstructions are cleared away. In addition,
ensure that the lay-down point is of adequate size and capable of
taking the weight of the load.

When lowering the load it should be brought to a halt a short distance

above the landing site to allow the operator to steady it, check the
position of the landing packing and ensure that all personnel have
their fingers and feet clear of the load.  The load should then be
inched down into position.  Before slackening off the slings, check that
the load is safe and stable.  If not, it should be lifted slightly (to allow
the landing packing to be adjusted) and lowered again.  The trial
landing procedure is very similar to the trial lift procedure and should
be repeated until the load is safely landed.

Safety Margins

When undertaking a multi-point lifting operation, for example where

two or more lifting appliances are used, steps must be taken to ensure
that no item of equipment or lifting point is at any time subjected to a
load in excess of its safe working load.

There are a number of ways of ensuring this according to the nature of

the operation, for example where total lifting capacity is not unduly
limited then, each lifting point together with its associated lifting
machine and tackle could be selected to be capable of sustaining the
entire load.

Alternatively, where the capacity is limited, the use of load sensors will
provide continuous guidance on individual lift-point equipment
loadings as the operation proceeds.  A further alternative is to
carefully calculate the loads, which will be imposed but care must be
taken to ensure that no false assumptions are made especially with
regard to the weight and the position of the centre of gravity.

In the case of rigid loads, consideration should be given as to how

many lifting points will bear the load at any time as in practice the
majority of the load may be taken on only two lifting points.  In such
cases the safe working load of each lifting point and its associated
equipment should not be less than half the total load.
Misuse of Equipment

Finally, always remember, the use of lifting equipment beyond its SWL
is strictly forbidden. Particular attention must be given to the
avoidance of over-loading, incorrect slinging and trapping of slings
between the load and the ground or floor.