GI-0007.024

Saudi Aramco 7180 (5/89) G.I. NUMBER

Approved

7.024

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) GENERAL INSTRUCTION MANUAL

ISSUE DATE

ISSUING ORG.

LOSS PREVENTION DEPARTMENT

SUBJECT:

MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING OPERATIONS

05/22/2001 APPROVAL

HJK

REPLACES

01/16/1996 PAGE NUMBER

1

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10

SCOPE: This instruction specifies the methods, procedures and responsibilities for installation, maintenance, and safe operation of marine and offshore cranes, hoists, and rigging. It applies to all cranes, hoists, and rigging used on boats, docks, barges, offshore platforms, and offshore GOSPs within Saudi Aramco facilities/projects, operated by Saudi Aramco and contractor personnel. Included are all mechanical, electrical, and hydraulic/ pneumatic powered stationary cranes and hoists.

CONTENT: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Objectives Definitions Applicable Codes, Standards, Regulations, & General Instructions New Installations and Modifications of Fixed Cranes Operator and Rigger Testing and Certification Equipment Inspection Maintenance Critical Lifts Operating Procedures

1.0

OBJECTIVES: 1.1

2.0

This instruction is intended to achieve the following: 1.1.1

Identify installation requirements for new marine and offshore cranes and rigging equipment.

1.1.2

Specify minimum requirements for licensing Saudi Aramco and contractor personnel who operate cranes, hoisting, and rigging equipment on marine/offshore Saudi Aramco facilities and projects.

1.1.3

Describe minimum requirements for inspecting, maintaining, and certifying marine and offshore cranes, hoists, and rigging equipment.

1.1.4

Outline general safe work practices which apply to crane, hoist, and rigging operations.

DEFINITIONS: Competent Person - A person who, by possession of a pertinent recognized degree, or certificate of professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to recognize, solve or resolve problems related to crane operation, design, or procedures.

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Authorized Saudi Aramco Representative - A member from proponent management, or from one of the recognized Crane Safety Committee organizations, i.e., Loss Prevention Department, Inspection Department, Roads & Heavy Equipment Department, and Job Skills Training Department. Home Country Certification - A certification for non-Saudi Aramco marine personnel from a recognized international institution. Examples are, but not limited to: ABS (Dubai), CITB (UK), Singapore Vocational & Industrial Training Board, US Navy, US Merchant Marine, Crane Tech (USA), or Emirate Safety Services. Ordinary Lift - Low risk lifts of ordinary items requiring no special rigging, and not considered critical lifts (see Section 8.). ACRONYMS ABS ANSI API ASME CITB CSD ID JSTD LPD PFD UK USA LRS

3.0

-American Bureau of Shipping -American National Standards Institute -American Petroleum Institute -American Society of Mechanical Engineers -Construction Industrial Training Board -Consulting Services Department -Inspection Department -Job Skills Training Department -Loss Prevention Department -Personal Flotation Device -United Kingdom -United States of America -Lloyd’s Register of Shipping

APPLICABLE CODES, STANDARDS, REGULATIONS, AND GENERAL INSTRUCTIONS: The following Standards and General Instructions apply to marine and offshore cranes, hoists, hooks, slings, rigging, personnel work platforms, and personnel carriers. Consulting Services Department shall resolve all disputes regarding conflicts between these Standards, and the appropriateness of substituting other international standards, i.e., British Standards or DIN. API Spec. 2C API RP. 2D ASME B30.2 ASME B30.3 ASME B30.4 ASME B30.5

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Specification for Offshore Cranes Recommended Practice for Operation and Maintenance of Offshore Cranes Overhead and Gantry Cranes Hammerhead Tower Cranes Portal, Tower, and Pillar Cranes Mobile and Locomotive Cranes

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ASME B30.6 ASME B30.8 ASME B30.9 ASME/ANSI B30.10 ASME B30.11 ASME B30.16 ASME B30.17 ASME B30.22 G.I. 2.100 G.I. 6.020 G.I. 7.025

**

G.I. 7.026

*

G.I. 7.027L G.I. 7.028 G.I. 7.029 G.I. 7.030

Approved

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Derricks Floating Cranes and Floating Derricks Slings Hooks Monorails and Underhung Cranes Overhead Hoists (Underhung) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist) Articulating Boom Cranes - Work Permit System - Personnel Floatation Devices for Work On, Over or Near Water - Mobile Heavy Equipment Operator Testing and Certification and Investigating Procedures - Cranes & Heavy Equipment Incident Reporting and Investigating Procedures - Personnel Work Platform Operations (Manbasket) - Crane Lifts: Types and Procedures - Inspection, Use and Maintenance of Below-the-Hook Lifting Equipment for Cranes - Inspection and Testing Requirements of Elevating/Lifting Equipment

Saudi Aramco Crane Safety Handbook Handbook for Riggers SOLAS Regulation 25-8 GUIDELINES ONLY ABS - 1991 - Guide for Certification of Cranes (guideline only) 29 CFR 1918 - Long Shoring, US-OSHA (guideline only)

4.0

* CHANGE

NEW INSTALLATIONS AND MODIFICATIONS OF FIXED CRANES: 4.1

Cranes, hoists, and rigging equipment shall be installed, extensively repaired, or modified in accordance with Section 3.0 Standards.

4.2

Specifications and designs for new Saudi Aramco fixed crane installations or for extensive repairs and modifications to existing cranes, shall be reviewed by CSD.

4.3

The proponent shall assure that all newly installed, modified, altered, or extensively repaired cranes receive a pre-operation acceptance inspection and proof-load test, witnessed and accepted by ID.

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COMPLETE REVISION

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5.0

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4.4

Copies of all proof-load test records and acceptance inspections shall be kept permanently on file by the proponent.

4.5

All fixed and mobile cranes on classed vessels require crane certification by a recognized classification society, e.g., ABS, LRS.

OPERATOR AND RIGGER TESTING AND CERTIFICATION: 5.1

Marine/Offshore Stationary Crane Operators: 5.1.1

5.2

All Saudi Aramco and contractor operators of major marine/offshore cranes shall be tested and certified by a representative of the Dhahran Heavy Equipment Operators Training and Test Unit/JSTD, normally at the work location. The major categories of cranes are: portal, tower, pillar, floating cranes, floating derricks, and barge mounted mobile cranes.

5.1.2

Operators of minor cranes shall be trained and approved by their department management. The minor crane categories include: pendant operated bridge cranes, jib cranes, monorail cranes, and fixed hoists. Marine/offshore crane operators shall have successfully completed the medical examination, as per Saudi Aramco Medical Technical Memo TM #1-7 or equivalent, when applying for initial certification, certification renewal, or approval of "Home Country" certification in the case of marine contractors. Contract operators must have undergone and retained evidence of equivalent medical examinations.

5.1.3

All operators shall carry a Saudi Aramco Crane Operators Certificate, for specified marine and offshore fixed or mobile cranes, which is valid for 3 years.

5.1.4

Exception: Non-Saudi Aramco marine crane operators without onshore access shall possess a valid "Home Country" certificate to be furnished to the proponent management, for review and approval, prior to operating any cranes on Saudi Aramco projects. All operators shall produce their certificate to any Authorized Saudi Aramco Representative upon request.

Marine/Offshore Riggers: 5.2.1

5.2.2

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Approved

7.024

All Saudi Aramco and contractor riggers in the marine/offshore areas shall be certified as a Rigger I, II, or III by the Job Skills Training Department (JSTD). Exception: Non-Saudi Aramco marine riggers without onshore access shall possess a valid "Home Country" certificate to be furnished to proponent management, for review and approval, prior to operations on Saudi Aramco projects. Riggers shall carry their rigger certificate which is valid for 2 years.

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5.2.3

6.0

7.0

8.0

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Riggers shall produce their certificate to any Authorized Saudi Aramco Representative upon request.

6.1

Daily pre-operational inspection of cranes and hoists shall be conducted by the operator before use. A checklist shall be used. Safety deficiencies shall be corrected before crane operation (for Saudi Aramco land cranes contact Roads & Heavy Equipment Department.) The checklist shall meet the minimum inspection requirements of the appropriate ANSI or API standard.

6.2

Rigger inspections: A Rigger I, II, or III, or an individual trained and certified by ID shall inspect slings, hooks, stationary hoists, eyebolts, shackles, lever actuated hoists, turnbuckles, etc. for damage before each use, rejecting equipment unfit for service. Sling identification tag or stamp shall state safe working load, sling serial #, manufacturer logo, etc., per G.I. 7.029.

6.3

Initial inspection of new, modified, or extensively repaired cranes shall be conducted according to Section 4.

6.4

Quarterly and annual inspections shall be performed by ID in accordance with Section 3 standards, and manufacturer's recommendations.

MAINTENANCE: 7.1

All cranes and hoists in the marine/offshore environment shall be maintained in accordance with the manufacturer's recommendations, and Section 3 standards.

7.2

Copies of maintenance and inspection records shall be kept on file by proponent management for a period of not less than 3 years.

7.3

Maintenance and inspection records will be made available to ID or LPD upon request.

CRITICAL LIFTS: 8.1

Critical lifts are defined as high risk lifts where there is a potential for serious injury, major property loss, or disruption of programs or projects. The following are examples of critical lifts: [Note: Low risk or low consequence lifts are not included.] around energized electrical lines near or over hydrocarbons and pressurized piping systems on barges, vessels, and hydrocarbon loading piers

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EQUIPMENT INSPECTION:

6.2.1

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around and over populated/traffic areas tandem, multiple or tailing lifts on rubber or pick and carry lifts personnel platforms (manbaskets) high level or long reach lifts 8.2

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8.3 *

9.0

* CHANGE

Lift plans are required for lifts falling under subsection 8.1 or for a lift when at least one vessel is afloat and the sea exceeds Sea State 3 or wind Beaufort Force Designation 4. 8.2.1

Lift plans shall be reviewed and approved before performing critical lifts Competent Person per G.I. 7.028. See sample lift plan attached.

by a

8.2.2

A lift plan may be reused for critical lifts that are repeated, and where conditions remain unchanged. This applies to multiple use of the same load configuration using the same lift equipment.

8.2.3

Repetitive use of a lift plan requires the counter signature of the responsible supervisor, or the person who originally approved the lift plan, before repeating any lift.

Lift Plans are not normally required for the following operations: 8.3.1

Ordinary lifts between two vessels where at least one vessel is afloat and seas do not exceed Sea State 3 or wind Beaufort Force Designation 4 (moderate breeze, small waves 1 m to 1.5 m; scattered whitecaps beginning to form); and within the crane's dynamic load chart.

8.3.2

Ordinary pier lifts onto or off vessels that are moored, provided that the lift is performed within the limits of the crane's dynamic load chart and seas do not exceed Sea State 3 or wind Beaufort Force Designation 4.

8.3.3

Ordinary lifts across water where both the crane and load landing site are on solid footing.

8.3.4

Ordinary offshore platform lifts may be performed over pressurized piping and hydrocarbon systems, provided it can be determined by a competent person before the lift that such systems are protected from damage resulting from a dropped load or crane accident.

OPERATING PROCEDURES: 9.1

Crane operations shall comply with requirements of pertinent Section 3 standards and the manufacturer's recommendations.

9.2

Critical Lifts and Multiple/Tandem Lifts shall comply with G.I. 7.028. (Follow the specific lift plan requirements for the critical lift.)

** ADDITION

NEW INSTRUCTION

COMPLETE REVISION

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ISSUING ORG.


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9.3

All cranes shall bear a valid Saudi Aramco inspection sticker prior to use as outlined in G.I. 7.030.

9.4

Rigging operations shall comply with the Handbook for Riggers and G.I. 7.029.

9.5

Personnel Work Platforms:

9.6

9.5.1

Crane suspended personnel work platforms (manbaskets) shall be certified by the manufacturer or a Competent Person, as having met the requirements of ANSI B30.5.

9.5.2

Personnel work platforms suspended from a crane hook shall be used as specified in G.I. 7.027, and G.I. 7.028.

9.5.3

Personnel work platforms shall not be used for personnel transfers between locations such as offshore platform to ship or ship to pier, except by divers with an approved lift plan.

9.5.4

All cranes used to lift personnel work platforms shall have anti-two block devices, power-controlled lowering (no free fall), and operated in accordance with G.I. 7.027.

9.5.5

All personnel on the work platform shall wear approved personal flotation devices (PFDs) when working over water (divers are exempt from this requirement.)

9.5.6

Personnel work platforms shall be inspected and approved by ID prior to use and bear a valid inspection sticker.

9.5.7

An approved manlift permit is required by G.I. 7.027 prior to conducting a personnel lift in a manbasket.

Personnel Carriers: 9.6.1

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Personnel carriers shall be used for personnel transfers in accordance with API 2D regulations, some of which are: 9.6.1.1

Crane hooks shall have a safety latch.

9.6.1.2

Lifts shall be under power control during both up and down travel.

9.6.1.3

An operable anti-two block device is required.

9.6.1.4

Personnel on the carrier shall wear approved personal flotation devices (PFDs).

9.6.2

Personnel carriers should be inspected and approved by ID prior to use and bear a valid inspection sticker.

9.6.3

Personnel carriers shall not be used as work platforms.

9.6.4

The rated capacity of personnel carriers shall be clearly placarded and shall not be exceeded.

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9.7

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Mobile Land Cranes on Vessels: 9.7.1

The proposed installation and use of vessel, barge, or pontoon mounted mobile land cranes shall be approved by the crane manufacturer, for use in an offshore work environment.

9.7.2

The vessel's deck strength and/or any reinforcement shall be verified by a competent person, as adequate to accommodate the foundation and dynamic loads resulting from the installation and operation of the crane.

9.7.3

Land cranes approved by the manufacturer for offshore operation shall be provided with dynamic load charts clearly stating the derated load capacities and applicable limiting environmental conditions on which the chart is based. The dynamic load chart shall be affixed to the crane cab as per ASME B30.8, and with appropriate warning notes.

9.7.4

The vessel shall carry on board stability information which includes offshore crane operations in accordance with SOLAS Regulation 25-8.

9.7.5

If a load moment indicating device (LMI) is provided on the land crane, it shall be calibrated and in good operating condition.

9.7.6

Land cranes shall be adequately supported and sea fastened according to an approved plan. The plan shall show foundation details, and securing arrangements for the unit, including hook block, headache ball, and boom support.

9.7.7

The superstructure swing brake and turn-table locking pin of the crane shall be fully operational and engaged in transit, or when the crane is idle.

9.7.8

The land crane installation shall be inspected and approved by ID prior to initial use.

9.7.9

Internal combustion engines shall be equipped with spark arrestors. Cranes operating in hazardous areas shall be equipped with all necessary explosion proof accessories to suit respective zone requirements (SA or UBC).

9.7.10 The crane shall be equipped with an audible alarm to signal all boom and hoist movements.

Recommended: Manager, Loss Prevention Department

Recommended: Manager, Inspection Department

Recommended:

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Manager, Roads & Heavy Equipment Dept.

Concurred: Manager, Marine Department

Concurred: Manager, Consulting Services Department

Concurred: General Manager, Training & Career Development

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Concurred: Sr. Vice President, Gas Operations

Concurred: Sr. Vice President, Oil Operations

Concurred: Sr. Vice President, Engineering & Operations Svcs.

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Concurred: Sr. Vice President, Refining, Supply & Distribution

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Approved: Exec. Vice President, Manufacturing Operations

Approved: Exec. Vice President, Exploration & Producing

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SAUDI ARABIAN OIL COMPANY (Saudi Aramco) Sam ple Lift Plan/ Offshore & M arine Organization: _________________________________________________ Date: ____________________________ W /O No.: __________________ Contract No.: ________________ Job Location: _______________________ S.O. ______________________ A ) Crane Type/M odel: ____________________ _______________________________________

Equipment No.: ________________ Current Insp. Sticker On Crane: Yes ___ No ___

B) Load Description: _________________________ ___________________________________________

N e t L o a d W eight: __________ (Lbs/K gs)

Stowed

Erected

N /A

(Lbs/K gs)

Jib: ? ? ? ________ Extension ? ? ? ________ 1. H i t c h A r r a n g e m e n t U s e d : _ _ _ _ _ _ _ _ _ _ _ _ _ Hookblock (Main) ___ ___ ___ ________ Aux Boom Head ___ ? ? ________ 2. Sling Type: ________________________ Headache Ball ___ ? ? ________ Slings, Shackles, etc. ___ ___ ___ ________ 3. Sling Size: ________________________ O thers ___________________________ ________ _____________________________ ________ 4. Capacity of Above Combinations: Total: _________________ Lbs(Kgs) (Gross Load W eight) ________ Note: If jib is used, refer to D ) Total Boom Length: _______________________ Ft(M ) proper load chart and safety notes on load chart. E) M aximum Required Operating Radius ________________ Ft(M ) C) Attachments & Rigging: _____________

F ) B o o m A n gle Limits of Operation: M ax. __________ ?

M in. __________ ?

G ) L o a d M o m e n t I n d i c a t o r C a l i b r a t e d a n d S e t-u p f o r t h e L i f t

?

Yes

No

?

H ) Maximum lifting capacity of crane in above configuration as per load chart and safety notes: __________________ I) W i n d F o r c e :

Beaufort Force Designation ___________

J) Seas – W hen at Least One Vessel is Afloat: K ) Outriggers fully extended & secured? For Barge Mounted Land Crane L ) B l i n d L i ft ?

W ind Speed ___________ (maximum allowable is 20 mph = 17.4 kts) W ave Height _________________

Yes Yes

? ?

REPETIVE USE OF LIFT PLAN? ORIGINATOR: Crane Operator Rigger Supervisor

Name: _________________________ _________________________ _________________________

YES Emp. No. ___________ ___________ ___________

?

No

?

No

? NO

?

Reviewed/Approved: Name: ______________________ Badge No. __________________ As per GI 7.028

Attachment Required: Sketch of Lift Site, Rigging Components, Load Attachment, and Obstacles * CHANGE

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GI-0007.024

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