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Saudi Aramco 7180 (5/89)

G.I. NUMBER Approved


7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 1 OF 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. Objectives
2. Definitions
3. Applicable Codes, Standards, Regulations, & General Instructions
4. New Installations and Modifications of Fixed Cranes
5. Operator and Rigger Testing and Certification
6. Equipment Inspection
7. Maintenance
8. Critical Lifts
9. Operating Procedures

1.0 OBJECTIVES:
1.1 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.

2.0 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.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 2 OF 10

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 -American Bureau of Shipping


ANSI -American National Standards Institute
API -American Petroleum Institute
ASME -American Society of Mechanical Engineers
CITB -Construction Industrial Training Board
CSD -Consulting Services Department
ID -Inspection Department
JSTD -Job Skills Training Department
LPD -Loss Prevention Department
PFD -Personal Flotation Device
UK -United Kingdom
USA -United States of America
LRS -Lloyd’s Register of Shipping

3.0 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 Specification for Offshore Cranes


API RP. 2D Recommended Practice for Operation and Maintenance of Offshore Cranes
ASME B30.2 Overhead and Gantry Cranes
ASME B30.3 Hammerhead Tower Cranes
ASME B30.4 Portal, Tower, and Pillar Cranes
ASME B30.5 Mobile and Locomotive Cranes

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 3 OF 10

ASME B30.6 Derricks


ASME B30.8 Floating Cranes and Floating Derricks
ASME B30.9 Slings
ASME/ANSI B30.10 Hooks
ASME B30.11 Monorails and Underhung Cranes
ASME B30.16 Overhead Hoists (Underhung)
ASME B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single Girder,
Underhung Hoist)
ASME B30.22 Articulating Boom Cranes
G.I. 2.100 - Work Permit System
** G.I. 6.020 - Personnel Floatation Devices for Work On, Over or Near Water
G.I. 7.025 - Mobile Heavy Equipment Operator Testing and Certification and
Investigating Procedures
* G.I. 7.026 - Cranes & Heavy Equipment Incident Reporting and Investigating
Procedures
G.I. 7.027L - Personnel Work Platform Operations (Manbasket)
G.I. 7.028 - Crane Lifts: Types and Procedures
G.I. 7.029 - Inspection, Use and Maintenance of Below-the-Hook Lifting Equipment
for Cranes
G.I. 7.030 - 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 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.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 4 OF 10

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.

5.0 OPERATOR AND RIGGER TESTING AND CERTIFICATION:


5.1 Marine/Offshore Stationary Crane Operators:

5.1.1 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.

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.
5.1.2 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.

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.
5.1.4 All operators shall produce their certificate to any Authorized Saudi Aramco
Representative upon request.

5.2 Marine/Offshore Riggers:

5.2.1 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.
5.2.2 Riggers shall carry their rigger certificate which is valid for 2 years.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 5 OF 10

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

6.0 EQUIPMENT INSPECTION:


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:

6.2.1 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.

7.0 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.

8.0 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

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 6 OF 10

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 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 by a
Competent Person per G.I. 7.028. See sample lift plan attached.
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.

8.3 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.

9.0 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.)

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 7 OF 10

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:

9.5.1 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.

9.6 Personnel Carriers:

9.6.1 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.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 8 OF 10

9.7 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:

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 9 OF 10

Manager, Roads & Heavy Equipment Dept.

Concurred:
Manager, Marine Department

Concurred:
Manager, Consulting Services Department

Concurred:
General Manager, Training & Career Development

Concurred:
* Sr. Vice President, Gas Operations

** Concurred:
Sr. Vice President, Oil Operations

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

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

Approved:
* Exec. Vice President, Manufacturing Operations

Approved:
Exec. Vice President, Exploration & Producing

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10


Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
7.024
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 05/22/2001 01/16/1996
SUBJECT: MARINE AND OFFSHORE CRANE, HOIST, AND RIGGING APPROVAL PAGE NUMBER
OPERATIONS HJK 10 OF 10

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)

C) Attachments & Rigging: _____________ 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 )

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 ___________ W ind Speed ___________


(maximum allowable is 20 mph = 17.4 kts)
J) Seas – W hen at Least One Vessel is Afloat: W ave Height _________________

K ) Outriggers fully extended & secured? Yes ? No ?


For Barge Mounted Land Crane
L ) B l i n d L i ft ? Yes ? No ?
REPETIVE USE OF LIFT PLAN? YES ? NO ?
ORIGINATOR: Name: Emp. No. Reviewed/Approved:
Crane Operator _________________________ ___________
Rigger _________________________ ___________ Name: ______________________
Supervisor _________________________ ___________ Badge No. __________________
As per GI 7.028

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

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION 10