SACYR MEDGULF HSE MANAGEMENT SYSTEMS MANUAL

CRANE LIFT PROCEDURE

1. SCOPE:
This procedure applies to ALL lifts made by mobile cranes including drotts, galions, cherrypickers, etc. to
the extent all lifts should be assessed under the risk assessment section of this procedure. “Critical Lifts
“defined as medium or high risk, will require full implementation of this procedure. “Routine Lifts “defined
as low risk, do not require implementation of this procedure. Lifts made by permanent or fixed lifting
equipment are not covered by this procedure.

2. PURPOSE:
The purpose of this procedure is to reduce the risk of personnel injury, property damage, and business
interruption when performing crane lifts any of Sacyr Megulf JV site & facilities. This procedure is intended
to ensure proper planning; hazard assessment, authorization, and recognized safe crane operating
methods are performed.

3. PROCEDURE:
A. Crane Lift Assessment
A risk assessment must be completed for all crane lifts in the facility. The Crane Lift
Assessment Table that is included must be utilized to conduct the crane lift assessment. Any
Medium or High level designation for any risk factor is considered a critical lift and will require
completion of a Critical Lift Permit and a pre-meeting to be conducted.

B. Hazard Assessment
A Job Safety Analysis must be conducted for lifts with multiple high risk factors to identify each
step in the lift, the hazards associated with each step, and any necessary safeguards relating
those job steps.

C. Equipment Setup and Operation

All instructions in the manufacturer’s operating manual for cranes to be used must be
referenced and followed. Any deviation from manufacturer’s instruction must be noted on the
Critical Lift Permit and approved by all personnel involved in the lift.

D. Pre-Lift Meeting
A pre-lift meeting must be held for all critical lifts (medium or high risk) with all personnel
involved in the lift present. All personnel involved in the lift must sign the Critical Lift Permit
acknowledging that the preparations are in place and the lift can be safely performed.

E. Critical Lift Permitting

A Critical Lift Permit for each crane used in the lift must be completed and signed by
applicable personnel prior to conducting a critica l lift. Whenever conditions or job steps are
changed or added, a new risk assessment, job safety analysis (for lifts with multiple high risk
factors), and a lift permit must be completed before the lift can proceed.

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4. CRANE LIFT RISK ASSESSMENT TABLE
The following table is intended to identify the risks associated with a particular crane lift. This
table may not cover all risk factors associated with crane lifts. Existence of multiple risk factors
may increase the risk of a particular lift. The person(s) performing the risk assessment should
always be conservative when assigning risk to a crane lift in order to ensure that all
precautions and safeguards associated with the risk level will be included.

CRANE LIFT RISK ASSESSMENT TABLE

Factor Risk High Level Risk
Process Lifting over operating
Condition process equipment
containing hazardous
material. Lifting over non-
operating process
equipment containing very
hazardous materials or
high volume high pressure
hazardous materials (i.e.,
hydrogen sulfide, liquefied
petroleum gas). Lifting
over equipment or facilities
that if damaged will have a
significant effect on the
integrity of process
operation. (MCCs, cable
trays,etc.)
Proximity to Operating equipment,
Personnel and control rooms, occupied
Equipment buildings within a distance
of 120% of the boom
length and load radius
centered on crane
turntable. See Lift Area
Diagram.
Property Loss Load to be lifted is high
And/Or cost (>$100,000) Long
Business lead time or project critical
Interruption path.
Medium Level Risk
Lifting over equipment which
is non-operating and isolated
from the process but which
contains hazardous
materials (i.e., C5’s and
above, chemicals, high
pressure steam, etc.).
Operating equipment,
control rooms, occupied
Buildings within a distance of
150% of the boom length
and load radius centered on
the crane turntable.
Load to be lifted is moderate
cost $50,000 to $100,000
with some project schedule
impact or some business
interruption.
Low Level Risk
Lifting over equipment
cleared of hazardous
materials.
All other lifts not within the
medium or high risk
proximity.
Load to be lifted is low cost.
(<$50,000) with
replacement readily
available. Minor or no
business interruption.

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Factor Risk High Level Risk
Complexity Load exceeds 90% of the
crane’s charted capacity
and: lift presents limited
clearance, multiple
maneuvers, multiple
cranes, difficult
alignment/placement,
specialized jib required,
and/or complicated
rigging.
Lift Equipment Any lift requiring a crane
with heavy lift
attachments, guy wires,
poles, or derricks
Height of Lift Any lift in which the
greatest length of the
boom utilized during the
lift is 80% or more of the
maximum boom length
and the crane is base
rated at 135 metric tonnes
or greater.
Weight of Load Any lift using an estimated
weight which exceeds
80% or more of crane
rated capacity.
Weather High wind velocity with
potential to interfere with
load/crane stability.
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Medium Level Risk Low Level Risk
Lift presents limited Clearance is no concern,
clearance, multiple routine rigging, single crane.
maneuvers, multiple cranes,
difficult
alignment/placement,
specialized jib required,
and/or complicated rigging
Crane base rated at 180 Routine plant lifting
metric tonnes or greater. equipment without
additional attachments.
Any lift in which the greatest All other boom length and
length of the boom utilized crane ratings.
during the lift is 80% or more
of the maximum boom
length and the crane is base
rated at 70 to 135 metric
tonnes.
Any lift using an known Weight determined to be
weight which exceeds 90% less than 90% of the crane
or more of crane rated rated capacity.
capacity. Counter weights
added per manufacturer’s
instruction.
Unstable weather conditions Low or no winds or known
with potential for sudden potential for winds to
high winds that may interfere develop and interfere with
with the safety of the lift. the lift.
3
5. RESPONSIBILITIES
A. Crane Operator

1. Must have approved operator’s certification and crane inspection certificate.

2. Participate in the risk assessment to determine the risk category for the lift.
3. Participate in the lift job safety analysis for lifts with two or more high risk factors.
4. Have current authorization to perform the lift with the applicable crane/equipment
5. Ensure the weight of the load and accessories has been established.
6. Assess the lift including weight of load, radius of boom, boom angle, weather
conditions, levelness of crane set-up, etc. to ensure the lift is within the load ratings
(load chart) of the crane as provided by the manufacturer.
7. Set-up crane in accordance with manufacturer’s equipment-specific instructions.
8. Perform a daily equipment inspection of the crane in accordance with manufacturer’s
equipment-specific instructions.
9. Ensure proper barricades are utilized to prevent unauthorized personnel from entering
crane and lift area.
10. Ensure flagman and signalman are used whenever necessary for safe travel and/or
operation.
11. Participate in the pre-lift meeting
12. Complete and sign Critical Lift Permit authorizing that all preparations and safeguards
are in place prior to making the lift.
13. Perform unloaded lift cycle test if the risk assessment includes 1 or more High Level
Risk factors.
14. Perform suspended load test by suspending load slightly above grade/equipment base
prior to making full lift cycle.
15. Perform the lift in accordance with recognized safe operating methods outlined by the
manufacturer and with the precautions listed in the lift job safety analysis (for lifts involving two
or more high risk factors).
16. Return completed Critical Lift Permit and Job Safety Analysis to supervisor in charge of the lift.

B. Rigger

1. Must have approved competence certification.

2. Participate in the risk assessment to determine the risk category for the lift.
3. Participate in lift job safety analysis for lifts with two or more high risk factors.
4. Have current authorization to perform rigging for the lift.
5. Ensure daily and periodic inspections are performed on all rigging and attachments prior to use.
6. Ensure the weight of the load and accessories has been established.

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 7. Participate in the pre-lift meeting.
8. Review and sign Critical Lift Permit authorizing that all preparations and safeguards are in place
prior to making the lift.
9. Rig the load in accordance with precautions listed in the lift job safety analysis and recognized
safe rigging methods.

C. Flagman/Signalman

1. Must have approved competence certification

2. Participate in the risk assessment as necessary to determine the risk category for the lift.
3. Participate in the lift job safety analysis for lifts with two or more high risk factors.
4. Have current authorization to perform signaling for the crane travel and/or lift.
5. Participate in the pre-lift meeting.
6. Review and sign Critical Lift Permit authorizing that all preparations and safeguards are in place
prior to making the lift.
7. Assist the crane operator with the unloaded lift cycle test.
8. Signal for the lift in accordance with precautions listed in the lift job safety analysis and
recognized safe methods.

D. Operations Team Leader/Supervisor

1. Participate in crane lift planning and crane lift process for lifts over process equipment.
2. Participate in the lift job safety analysis.
3. Assist the crane operator with preparing the area where the lift will occur.
4. Participate in the pre-lift meeting.
5 Review and sign the Critical Lift Permit authorizing that all preparations and safeguards are in
place prior to making the lift.

E. Maintenance Superintendent and/or Contractor Foreman

1. Responsible for the lift.

2. Participate in crane lift planning and crane lift permit process for lifts involving two or more high
risk factors.
3. Ensure lift preplanning is conducted including a lift job safety analysis.
4. Evaluate the need for outside expertise in planning and conducting the lift.
5. Ensure that authorized personnel are assigned to the lift.
6. Participate in the pre-lift meeting.
7. Review and sign the Critical Lift Permit authorizing that all preparations and safeguards are in
place prior to making the lift.

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 F. Safety Supervisor

1. Participate in the lift job safety analysis whenever lifts will be made over processes or equipment
AND the lift involves two or more high risk factors.
2. Ensure lift pre-planning is conducted including a lift job safety analysis.
3. Participate in the pre-lift meeting.
4. Review and sign the Critical Lift Permit authorizing that all preparations and safeguards are in
place prior to making the lift.

G. Safety Representative
1. Participate in the job safety analysis as necessary for lifts involving two or more high risk factors.
2. Participate in the pre-lift meeting.
3. Review and sign the Critical Lift Permit authorizing that all preparations and safeguards are in
place prior to making the lift.

H. Emergency Response Supervisor

1. Participate in the lift job safety analysis whenever lifts will be made over processes or equipment
containing hazardous materials AND the lift involves two or more high risk factors.

2. Identify potential incident scenarios resulting from lift failure and conduct emergency response

pre-planning.

3. Ensure adequate emergency response resources are available or staged in accordance with pre-
plans.
4. Participate in the pre-lift meeting.

I. Contract Management

1. Ensure that all contractors providing crane services are evaluated and qualified
2. Ensure all contractors providing crane services are qualified for crane inspection, repair, and
operation.
3. Ensure all contractors providing crane services have training programs and personnel are
properly trained and competent.
4. Maintain records of contractor qualifications, completed Critical Lift Permits, and completed Job
Safety Analysis.

7. DEFINITIONS
A. Anti Two-Block Device
A device which, when activated, disengages all crane functions that can cause two-blocking.
B. Authorization/Qualification
Approval and designation to perform crane operation, rigging, or signaling. Authorization will be

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 granted based on experience, training and/or certification.
C. Boom
A member hinged to the rotating superstructure and used for supporting the hoisting tackle.
D. Boom Angle
The angle above or below the horizontal measured from the longitudinal axis of the crane
turntable.
E. Boom Length
True length of the boom installed on the crane including any jibs, or extensions.

F. Counterweight
Weight used to supplement the weight of the crane to provide additional stability for lifting loads.
G. Critical Lift
Any crane lift that is determined to be” Medium” or “High” level risk for any of the risk factors listed
in the Crane Lift Risk assessment Table.

H. Jib
An extension attached to the end of the boom to provide added boom length for lifting specified
loads. The jib may be vertically in line with the boom or offset to various angles in the vertical
plane of the boom.

I. Load Rating
Crane capacity ratings in metric tonnes established by the crane manufacturer as provided in the
crane load chart.

J. Outriggers
Extendible or fixed members attached to the crane base used to support the crane.

K. Routine Lift
Any crane lift that is determined to be “Low” level risk for any of the risk factors listed in the Crane
Lift Risk Assessment Table.

L. Two-Blocking
The condition in which the lower load block or hook assembly comes in contact with the upper
load block or sheave assembly near the end of the boom.This condition can cause crane damage
and may cause the load to drop.

8. CRITICAl LIFT PERMIT

(See attachment)

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 CRITICAL LIFT PERMIT
LOAD
LOAD CONDITION: ( ) NEW ( ) USED

LOAD WEIGHT (metric tonnes) ‫ڤ‬ ESTIMATED‫ڤ‬ PROVIDED BY: ________

JIB
JIB TO BE USED: ( ) NO ( ) YES ( ) ERECTED ( ) STOWED

LENGTH OF JIB: ANGLE OF JIB: WEIGHT OF JIB:

RIGGING
SLINGS/CHOKERS RATING: LENGTH: NUMBER: SIZE: WEIGHT:
METAL
FABRIC
SHACKLES: RATING: NUMBER: SIZE: WEIGHT:
SPREADER BAR: RATING: NUMBER: SIZE: WEIGHT:
TAG LINES: LENGTH: NUMBER: SIZE: WEIGHT:
WIRE / CABLE: SIZE: WEIGHT:
BALL / HOOK: RATING: WEIGHT:
OTHER LIFTING RATING: NUMBER: SIZE: WEIGHT:
DEVICES
TOTAL RIGGING
WEIGHT:
LOAD WEIGHT:
WEIGHT OF JIB:
TOTAL WEIGHT
LIFTED AT BOOM
POINT:

CRANE
TYPE OF CRANE: CRANE SIZE/CAPACITY:

BOOM LENGTH: WORKING RADIUS: MAX BOOM ANGLE:

PARTS OF LINE: SWL OF LINE: MIN BOOM ANGLE:

HOIST: ( ) MAIN ( ) AUXILIARY

RATINGS OF ALL RIGGING COMPONENTS, BALL, HOOK, AND SWL OF LINE ADEQUATELY ( ) YES ( ) NO
ABOVE TOTAL WEIGHT LIFTED AT BOOM POINT

LOAD RATING OF CRANE FROM LOAD CHART

(mt)

LOAD RATING OF JIB FROM LOAD CHART

(mt)

TOTAL WEIGHT LIFTED IS % OF CRANE LOAD RATING

TOTAL WEIGHT LIFTED IS % OF JIB LOAD RATING

CRITICAL LIFT PERMIT

DATE: LOCATION: JOB/WO NUMBER:

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LIFT DESCRIPTION:
RISK LEVEL ASSIGNED FROM RISK ASSESSMENT TABLE:

All applicable items on the permit have been answered “YES”

and communicated to all personnel involved with the lift:
JOB SAFETY ANALYSIS COMPLETE YES NA CRANE OPERATOR (all lifts)
EMERGENCY RESPONSE PRE-PLANNING COMPLETE AND YES NA RIGGER (all lifts)
RESOURCES AVAILABLE
AUTHORIZED/QUALIFIED CRANE OPERATOR YES

AUTHORIZED/QUALIFIED RIGGER YES FLAGMAN/SIGNALMAN (if required for lift)

FLAGMAN / SIGNALMAN AVAILABLE IF REQUIRED YES NA OPERATIONS TEAM LEADER (lifts over process
equipment)
CRANE HAS CURRENT PERIODIC INSPECTION YES

DAILY CRANE INSPECTION COMPLETED * YES MAINTENANCE TL / CONTRACTOR SUPERVISOR

ALL SLINGS, CHOKERS, ROPES, AND OTHER RIGGING H YES PLANT MANAGER (lifts over process equipment AND
AVE CURRENT PERIODIC INSPECTION * existence of two or more high risk factors)
PRE-USE INSPECTION OF SLINGS, ROPES, CHOKERS AND YES SAFETY REPRESENTATIVE (two or more high risk
o OTHER RIGGING COMPLETED * factors)
CRANE SET-UP IN ACCORDANCE WITH MANUFACTURER’S YES EMERGENCY RESPONSE SUPERVISOR (lifts over
INSTRUCTIONS/MANUAL process
SMOOTH SOLID FOUNDATION IN THE CRANE SET-UP YES equipment AND existence of two or more high risk factors)
AREA WITH NO DEVIATIONS. UNDERGROUND
INSTALLATIONS CONSIDERED AND NOT IMPACTED
OUTRIGGERS EXTENDED AS FAR AS POSSIBLE, ON YES NA ADDITIONAL COMMENTS:
LEVEL, FIRM GROUND WITH SUPPORTS (MATS)
INSTALLED WHERE REQUIRED
TIRES COMPLETELY OFF GROUND WHEN OUTRIGGERS YES NA
USED
TIRES FULLY PRESSURED WHEN LIFTING OFF RUBBER YES NA
EXTENDIBLE COUNTERWEIGHT OUT IF PROVIDED YES NA
AREA COMPLETELY BARRICADED TO REMOVE YES
PERSONNEL FROM AROUND CRANE AND LIFT AREA
ANTI TWO BLOCKING SAFEGUARD IN PLACE AND TESTED YES NA
ALL NECESSARY CLEARANCES EVALUATED INCLUDING YES
OVERHEAD POWER LINES
UNLOADED LIFT CYCLE TEST PERFORMED IF REQUIRED YES NA
ALL REQUIRED SAFEGUARDS AND ACTIONS OF THE JOB YES NA
SAFETY ANALYSIS IN PLACE AND COMMUNICATED
SUSPENDED LOAD TEST PERFORMED YES

*Copies of these inspections are to be included with Critical Lift Permit

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9. Crane Lift Flow Chart

START

NO NO
Conduct Crane Medium Risk
Multiple High
Crane Lift (s) Lift Assesment Low Risk OR
Risks
High Risk

YES YES
YES

Prpeare Critical Prepare Critical

Conduct Lift Lift Permit Lift Permit

Conduct Pre-Lift
Conduct JSA
Meeting

Sign Critical Lift

Conduct Pre-Lift
permit
Meeting

Sign Critical Lift

Conduct Lift Permit.
Requires
signatures from
Plant MGR.
Safety Rep
Emergency
Resp.

Conduct Lift

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