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Basra And Baghdad Field

Lifting Operations Procedure

Rev Date Purpose of revision

0 August 2014 General review

1 November 2016 Three level Lifting Equipment Management System


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CONTENTS

1. GENERAL ...................................................................................................................... 3

1.1 Reference documents .................................................................................................. 3

1.2 Application ................................................................................................................... 4

2. PURPOSE ..................................................................................................................... 4

3. ROLES AND RESPONSIBILITIES ................................................................................. 4

4. DEFINITIONS ................................................................................................................ 5

4.1 Lifting Tools ................................................................................................................. 5

4.2 Lifting Gear .................................................................................................................. 8

4.3 Hoist .......................................................................................................................... 10

5. INSTRUCTIONS .......................................................................................................... 10

6. LIFTING TOOLS .......................................................................................................... 11

6.1 Maintenance and inspection....................................................................................... 11

6.2 Support, anchoring and fixing ..................................................................................... 11

6.3 Drums and Pulleys ..................................................................................................... 11

6.4 Brakes, Controls, Safety Devices, etc. ....................................................................... 11

6.5 Stability of Lifting Tools .............................................................................................. 12

6.6 Cranes with Derricking Jibs ........................................................................................ 12

6.7 Testing and Examination of Cranes and other Lifting Tools........................................ 12

6.8 Marking of Safe Working Loads ................................................................................. 13

7. LIFTING GEAR: CHAINS, ROPES, etc. ....................................................................... 13

7.1 Testing, Examination and Safe Working Load ............................................................ 13

7.2 Hooks ........................................................................................................................ 14

7.3 Slings ......................................................................................................................... 14

7.4 Protection of Edges.................................................................................................... 14


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7.5 Knotted Chains and other lifting tools ......................................................................... 14

8. CARRIAGE OF PERSONS AND SECURENESS OF LOADS ...................................... 14

8.1 Carrying of Persons by Means of Lifting Appliances .................................................. 14

8.2 Secureness of Loads and Personnel.......................................................................... 15

9. SIGNALS ..................................................................................................................... 15

10. CLASSIFICATION OF LIFTS ....................................................................................... 17

10.1 Non-Critical Lifts......................................................................................................... 17

10.1.1 Routine Lifts .......................................................................................................... 17

10.1.2 Simple Lifts ........................................................................................................... 17

10.2 Critical Lifts: Complicated & Complex ........................................................................ 18

10.2.1 Complicated Lifts .................................................................................................. 18

10.2.2 Complex Lifts ........................................................................................................ 19

11. RECORDS ................................................................................................................... 20

12. Three Level Lifting Equipment Management System.................................................... 21

Appendix 1: Lifting Operation Categorization Form ............................................................. 22

Appendix 2: Lifting Operation Plan ...................................................................................... 23

Appendix 3: Three Level Lifting Equipment Management System… ................................... 25

Appendix 4: Heavy equipment Blacklist / Register............................................................... 25

1. GENERAL

1.1 Reference documents


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Reference Title
AJIC-HSE-0001-00 PtW Procedure
AJIC-HSE-0002-00 Execution of Jobs not Requiring PtW

1.2 Application
This Procedure applies to all AJIC Departments including, but not limited to, Operations,
Construction, Drilling, HSE and Infrastructure and covers all operations involving the use
of any lifting equipment irrespective of size, weight and arrangements at locations in
AJIC Contract Area.

2. PURPOSE
To outline the requirements for managing and controlling lifting operations in Basra
field.

3. ROLES AND RESPONSIBILITIES


Site Authority / Operation Supervisor

To ensure that all lifting operations are adequately planned and executed and that all lifting
equipment used on site conforms to this procedure.

To coordinate with all members of the operations team and contractors on all matters related
to lifting operations such as erection, certification and maintenance of all lifting tools.

Review and approve the Qualifications of the person designated as Lifting Supervisor.

Site HSE Supervisor

Site HSE Supervisor is to ensure that all persons involved in the lifting operations are
competent and lifting operations are performed in compliance with HSE requirements.

Lifting Supervisor

The role of the lifting supervisor is to ensure that:

The crane operators carry out their duties safely. His other duties include assessment of
lifting operations by providing information on type of crane to be used, lifting gear and
equipment, instructions and supervision of the operation.

Adequate inspection and maintenance of the equipment has been carried out in accordance
with applicable maintenance schedule.

Lifting Operators

Responsible for the correct operation of the crane and other lifting equipment in accordance
with the manufacturing instructions and applicable documents.
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Must understand the duties of the slingers and banksmen with full understanding of the
signals used:

Ensure the crane and other lifting equipment is in good working condition by regular
documented inspection;

Be able to judge distances, height and clearances, and not be colour blind;

Know the means of escape and safe use of fire extinguishers;

Every crane operator shall pass on-job training confirmed by a certificate and shall be
included in the list of operators authorized by GPNB to operate the crane.

Riggers should be trained and competent for the task and must:

Determine the weight, center of gravity and characteristics of a load.

Be able to inspect and determine whether a wire rope sling or other piece of lifting
equipment is damaged or not fit for purpose.

Use of the correct lifting gear and equipment in accordance with the operations schedule.

Be responsible for:

- attaching and detaching the load to and from the crane load lifting attachment

- Inspection of rigging equipment to ensure it is in good condition.

Banksman should:

Be familiar with the different and correct slinging techniques.

Know the correct hand signals and relay the signal to the crane operator.

Direct movement of the crane and load.

4. DEFINITIONS

4.1 Lifting Tools


Tools used for raising or lowering a load:
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 Crab

 Winch

 Pulley block/hoist
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 Gin wheel

 Crane, etc.
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4.2 Lifting Gear


A chain, sling, rope sling, hook or similar gear:

 Link

 Plate clamp
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 Shackle

 Swivel

 Eye-bolt
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 Pad eye

4.3 Hoist
A lifting machine, whether worked by mechanical power or not, with a carriage, platform
or cage the movement of which is restricted by a guide or guides, but does not include a
lifting tool used for the movement of trucks or wagons on a line of rails.

5. INSTRUCTIONS
It’s critical to follow instruction with regard to lifting equipment and operations to ensure
safety compliance and to prevent incidents involving the failure and damage of lifting
equipment which are still frequent on work sites, and the consequences are usually very
severe when incidents do occur.

Factors leading to such accidents include:

Operator error, lack of competency or training.

Inadequate supervision, inspections and maintenance of equipment.

Failure to plan the operation, assess all risks and take precautions against overhead power
lines, other obstructions, poor ground and site conditions, poor visibility / insufficient lighting.

Overloading and misuse of equipment.

The following safe practices must be adhered to for all lifting operations as it will assist
in reducing the risks associated with such hazardous operations.

All machines and equipment associated with lifting work will be inspected by a designated
inspector or inspection team prior to being allowed to operate at GPNB work sites.
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For normal lifting activities, a safety boundary of 1.2 times the Safe Working Load (SWL) will
be required for all lifts. Critical lifts may require a greater safety boundary, which may be as
high as 2.0-3.0 depending on the risk to people and equipment.

No lifting activities will take place after sunset or before sunrise without special written
permission of the HSE Authority.

6. LIFTING TOOLS

6.1 Maintenance and inspection

Lifting tools have to be properly constructed and strong enough for the work for which they
are to be used.

Carefully inspected weekly by contractor representative person. A record of these


inspections must be kept.

6.2 Support, anchoring and fixing

Foundations, scaffolds, derrick masts, anchorages, guys etc., which have to support Lifting
tools must be strong enough for the working conditions.

Winch frames must be made of metal.

Ropes, chains, etc. used in erection or dismantling, must be properly connected to strong
attachment points.

Crane jibs (all sections) must be marked to indicate the crane to which they belong.

6.3 Drums and Pulleys

The size of the drum or pulley must match the size of the rope or chain.

There must never be less than two "dead" turns of rope on the drum.

Ropes and chains must be anchored to the drum.

6.4 Brakes, Controls, Safety Devices, etc.

All cranes, crabs and winches must be fitted with brakes capable of holding and controlling
their maximum loads.
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Control handles, levers, switches, etc., on all lifting Tools must be designed so that they
cannot be operated accidentally and must be marked to show what they are for and how
they should be operated.

6.5 Stability of Lifting Tools

When a crane (with or without outriggers), excavator, etc., is to be used on a slope, or on


uneven or soft ground, precautions must be taken to prevent overturning (e.g. by reducing
the slope, levelling the ground, or using mats).

Whenever any alterations to the anchorages or ballast are made, the anchoring and
ballasting must be checked, before the crane is put to work, by applying a load twenty five
per cent higher than the maximum rated load (an equivalent test with a lesser load is also
permissible). This test must be made so that the maximum pull is applied to the anchorage
or ballast.

If the test shows that the crane cannot be operated safely at its normal safe working load,
the crane can still be used if it is sufficiently de-rated and a modified loading diagram is fixed
on the crane where it is readily visible to the driver.

6.6 Cranes with Derricking Jibs

If the derricking motion is driven by the hoist motor through a clutch and can only be
controlled by the hoist brake, an interlock must be fitted to the clutch control lever and the
pawl and ratchet on the derricking drum.

This interlock must only allow the clutch to be withdrawn when the pawl is fully engaged in
the ratchet and the pawl to be disengaged when the clutch is in the driving position.

Hoisting mechanisms must be used only for vertical raising or lowering operations, unless
the operation is under the supervision of a person competent to ensure that is can be done
safely and without damage to the crane.

Crane jibs must not be worked except with written authorization of AJIC.

6.7 Testing and Examination of Cranes and other Lifting Tools

Cranes and Winches

These must be tested and thoroughly examined on arrival and at six month intervals there
after every four years.
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The test and through examination must be repeated after any disassembly, adjustment or
repair which affects the strength or stability of the crane or winch.

The thorough examination only must be repeated every 12 months and after substantial
changes or repair.

All Lifting Equipment, Lifting Gear, and Hoists must be labelled with an inspection tag
showing relevant details of the inspection.

6.8 Marking of Safe Working Loads


Cranes

 All cranes must be marked clearly with their maximum safe working loads.

 If the lifting radius can be varied, the crane must be marked with the safe
working load at various radius and an indicator must be fitted which shows the
safe load at each operation radius.

 Derricking cranes must be marked with the maximum operating radius of the jib.

Winches

 All winches must be clearly marked with their maximum safe working load (or
loads).

Indication of Safe Working Load on Jib Cranes

 Jib cranes must be fitted with an approved automatic safe load indicator.

 Automatic indicators must be kept in good order. They must be inspected each
week and records shall be maintained.

 Indicators must be tested by a competent person.

 Load should not to exceed the Safe Working Load, except only for testing
purposes, no machine or equipment used for lifting may be used to lift loads
greater than the specified safe working load.

7. LIFTING GEAR: CHAINS, ROPES, etc.

7.1 Testing, Examination and Safe Working Load


All ropes, chains and loose lifting gear must be thoroughly examined monthly. A log of
inspections shall be maintained and equipment tagged and/or colour-coded.

All ropes, chains and loose gear used for lifting must be fabricated for the purpose and be
strong enough for the work.
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Wire ropes, chains and lifting gear must not be used unless they have been tested and
examined. A record of the test and examination, showing the particulars given must be
obtained for each item.

All ropes, chains, and lifting gear must be marked with their safe working load and an identity
mark.

A wire rope must not be used when more than five per cent (one in twenty) of the wires can
be seen to be broken in any ten diameter length.

Ropes, chains and lifting gear must never be overloaded except when under test and as
authorized by a competent person.

7.2 Hooks
All hooks used for lifting must be fitted with a safety catch, or shaped to prevent the sling eye
or the load from coming off the hook (e.g. a "C" hook).

7.3 Slings
Rope or chain slings must be properly attached to the crane hook (or other part of the lifting
plant or lifting gear), e.g. by a ring or a thimble and eye, so that no damage is caused to the
sling or lifting gear.

Multiple slings (two legged, three legged, etc.) must have their legs connected by a ring or
shackle and the load must be properly distributed so that no leg is overloaded.

7.4 Protection of Edges


Packing must be used over all sharp edges, etc., to prevent damage to lifting ropes, chain or
rope slings.

7.5 Knotted Chains and other lifting tools


Loads must not be raised, lowered or suspended by:

Any wire, rope or chain in which a knot has been tied (i.e. ropes and chains must not be
shortened by tying knots in them).

Any chain which has been shortened or joined to another by bolts passed through the links.

8. CARRIAGE OF PERSONS AND SECURENESS OF LOADS

8.1 Carrying of Persons by Means of Lifting Appliances

Where persons have to be raised, lowered or carried to their workplace by a power-driven


lifting tools, a hoist or a properly constructed and maintained, suspended scaffold must be
used whenever reasonably practicable. Where this is not possible, aerial cableways or
ropeways, or cranes with buckets, may be used provided that they are:
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- Properly constructed and maintained;


- Inspected and tagged;
- Equipped with primary and secondary fall protection system to stop persons
from falling out;
- Not used to carry construction equipment or materials;
- Prevented from spinning or tipping;
- Load-tested to provide a 2:1 ratio of SWL expected maximum working load
(witnessed by Company);
- Clearly marked to indicate both SWL and maximum number of persons
permitted.

8.2 Secureness of Loads and Personnel

All loads must be secured to prevent any part slipping and falling, i.e. correctly loaded and
slung.

Precautions must be taken as far as reasonably practicable to prevent loads in transit from
knocking anything down and thereby causing danger.

Loose materials, e.g. bricks or slates, etc. must be lifted in a properly designed box, cage or
other container.

Whenever the load on a lifting tool is suspended, the driver must stay at the controls
throughout the operation.

Positive, pro-active measures must be used to keep non-lifting personnel away from lifting
zones, i.e. by placing barriers and etc.

Suspending all activities: if the wind is greater than 12 m/c, heavy rains, heavy winds,
<100m visibility.

9. SIGNALS
All signals (hand, mechanical or electrical) must be clear and distinct.

Handheld radios (walkie talkies) will be available at all times to crane operators, signalmen,
and riggers with critical roles or out-of-site situations, or in other scenarios as dictated by a
Lifting Plan.

AJIC shall establish and enforce a common, internationally recognized signalling system;
this system for signalling will be taught, used and referenced on AJIC site.

Standard hand signals for controlling crane operations, locomotive and truck cranes:
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10. CLASSIFICATION OF LIFTS

Before starting any lifting operation, whether done with a crane or other lifting tool, it has
to be classified into two main categories:

 Non-critical lifts (Routine and Simple)


 Critical lifts (Complicated and Complex)

Classification of Lifts shall be done using Lifting Operations Categorization Form in


Appendix 1.

10.1 Non-Critical Lifts

10.1.1 Routine Lifts


Uncomplicated lifts performed on a regular basis, utilizing fixed and / or dedicated lifting
equipment. Examples of this type of lifting operation include normal crane operations of
pre-slung equipment (or easily slung items such as tubular) and / or the use of pre-
installed rigging equipment such as chain hoists to lift a load, where the load is directly
beneath the hoist.

Routine non-critical lifts may be exempt from Permit to Work (considered as routine
activities) following procedure AJIC-HSE-0002-00, Execution of Jobs not Requiring PtW.
A corresponding initial lifting plan must exist and should be reviewed regularly (annually)
to make sure it is still valid.

To perform non-critical lifts (routine) the following documents are required on-site for
each lift:

- Lifting plan with layouts, sketches (slinging types and scheme, types of lifting
equipment and etc.), crane’s charts;
- Job Safety Analysis (JSA);
- Completed Categorization Form – Appendix 1.

Required documentation for non-critical lifts should be prepared by the relevant Lifting
Supervisor and approved by Site and Zone Authorities.

Toolbox talk covering the details of the task should normally be sufficient for this type of
lift.

10.1.2 Simple Lifts


This type of lifts involves basic hoisting equipment used for a simple operation, (i.e. not
requiring special rigging skills). This would involve direct lifting using certified lifting
equipment suspended from dedicated lifting points such as pad eyes or runway beams
e.g. utilizing portable lifting gear slung from a dedicated pad eye to lift a motor with
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specified lifting points. Such lifts are considered Simple non-critical lifts, if not included in
Routine Non-Critical Lifts per AJIC-HSE-0002-00, Execution of Jobs not Requiring PtW.

To perform Simple non-critical lifts the following documents are required on-site for each
lift:

- Lifting plan with layouts, sketches (slinging types and scheme, types of lifting
equipment and etc.), crane’s charts;
- Lift specific Job Safety Analysis (JSA);
- Toolbox talk before lifting operations covering the JSA;
- Completed Categorization Form;
- PTW.

Required documentation for non-critical lifts should be prepared by the relevant Lifting
Supervisor and approved by Site and Zone Authorities.

10.2 Critical Lifts: Complicated & Complex

For any critical lifting the following documents are required on-site for each lift:

- Lifting plan with layouts, sketches (slinging types and scheme, types of lifting
equipment and etc.), crane’s charts;
- Job Safety Analysis (JSA) should be prepared by a team consisting of the
person carrying out the task, task supervisor and the Area Authority;
- Toolbox talk before lifting operations covering the tasks of JSA;
- Completed Categorization Form;
- PTW

Required documentation for critical lifts should be prepared by the relevant Lifting
Supervisor and approved by Site and Zone Authorities.

10.2.1 Complicated Lifts

Complicated lifts represent a difficult task due to the nature of the load and / or lift
requirements. For example, loads with an awkward shape, offset or high centre of
gravity, fragile loads, loads containing liquids, no lifting attachments / difficult to sling etc.
The actual lifting operation / handling of the lift may also be difficult. For example; it may
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require to be rotated, have restricted headroom or it requires being cross-hauled


involving two or more sets of rigging gear etc.

Planning and Recommended Level of Risk Assessment:

- Typically, the risk assessment is completed through JSA prepared by the team
consisting of the person carrying out the task, Lifting Supervisor, Site and HSE
Authority;
- Zone authority is to review risk assessments;
- Critical Lifts require continuous presence of the Lifting Supervisor during such
operations.

10.2.2 Complex Lifts

These are complicated lifting operations with additional hazards and considerations.

For example moving extremely heavy loads, lifts involving confined spaces entry,
restricted headroom, lifting over unprotected plant or equipment, tandem lifts with
cranes, i.e. lifting operations or conditions which would require additional engineering
input.

Planning and Recommended Levels of Risk Assessment:

- Similar JSA format to “Complicated” but performed with all relevant Area and
HSE Authorities input;
- Zone authority to review risk assessments;
- Assessed as a new task each;
- Requires continuous presence of the Lifting Supervisor during operations.

Thus, all Lifting Operations, with the exception of Routine Lifts (item 10.1.1), are
considered to involve increased risk of incident and are performed under Company
Permit to Work System.

The purpose of the Permit to Work is to ensure that contractors responsible for the lifting
operation plan consider all the safety control elements prior to the commencement of
any critical lifting activity.

The Lifting Supervisor (Company or Contractor) applies for the Permit to Work from
GPNB Zone/Site Authority who then decide to either authorized / or reject the activity to
be performed due to safety reasons.

Company HSE Authority is to be trained and competent to recognize potential hazards


of lifting operations. A copy of the current Permit to Work must be kept in the crane and
available for inspection.
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Any lift carried out without the issue of the necessary permit will be stopped and the
person in charge will be subject to disciplinary action.

11. RECORDS
The following shall be maintained as a minimum;

- Regular lifting equipment inspection reports.

- Valid operators’ certificates.

- Records of all lifting tools (cranes, lifting gear, hoist, etc.)

- Third party crane inspection certificate, security pass.

- Anchorage and stability tests.

- Automatic indicator tests.

- Required Permits and other documents.

Records shall be maintained both electronically and hard copy and shall remain on site
for the duration of the project. However, operators’ licenses shall be maintained by
themselves and shall be present on site at all times.

Following any test, crane audit and examination, the following information must be
recorded.

Description, date of manufacture, identification mark and location of the equipment referred
to.

The safe working load (or loads) and (where relevant) corresponding safety radii, jib (boom)
lengths and counterweights.

Details of the test and examination carried out.

Date (or dates) of completion of the test, test and examination.

A declaration that the information is correct and that the equipment has been tested and
examined in accordance with the appropriate provisions and is found free from any defect
likely to affect safety.

Name and address of the owner of the equipment referred to.

Name and signature of the GPNB approved person declaring that the test and thorough
examination has been carried out.
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12. Three Level Lifting Equipment Management System


Three Level Lifting Equipment Management System is a part of System of Lifting
Equipment Management.

LEVEL 1. Subcontractor receives compliance certificate for Lifting Equipment from 3rd
Party.

LEVEL 2.

- Contractor initiates pre-start inspection for Lifting Equipment (LE) (following


conditions must be fulfilled)

- Contractor HSE Data Coordinator ( or other responsible person) collects all


information about passed LE and prepares ( updates) LE register

- Lifting Supervisor uses LE Register for future planning of monthly inspection


( Using the Color- coding system for access LE on the Construction site)

- Providing LE Register and inspection results to AJIC for verification ( usually at


the end of recent month)

LEVEL 3. Random GPNB Inspection of LE in accordance with provided LE Register

Based on the Inspection results there are two ways for LE using:

 Approve using LE on the Construction Site

 Violation observed during the inspection of the LE.

In case of critical noncompliance LE will be included in the Black List / Register


(Appendix 4) and remove from the Site.

The information about equipment included in the register also will be sent to AJIC
Security Department and security pass (clearance allowances) will be suspended
immediately

Schematic vision of Three Level Lifting Equipment Management System is shown in the
Appendix 3
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Appendix 1: Lifting Operation Categorization Form

Filled by:

Reviewed by: Lifting Supervisor


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Appendix 2: Lifting Operation Plan

LIFTING OPERATION PLAN (Specific □ / Generic □)


Company name:
Location: Area:

Is Diagram/Sketch and competent engineer calculations of Lifting Operation available?


(Mandatory for Specific Lifting Operation Plans)
Description of Lifting Operation:

Lift Category: Routine: Non-Routine:

Weight of Load: Actual □ / Assessed □ (check as appropriate)

Lifting Equipment & Accessories to be used (specify type, SWL and results of pre-job inspection):

All Lifting Operations require the following to be considered but this list is not exhaustive.

□ Cultural, communication and language difficulties. □ Environmental conditions including weather


□ Weight, size, shape and center of gravity of load and permissible limits.
□ Availability of approved lifting points on load □ Lighting in the pick-up and lay-down areas
□ Method of slinging/attaching/detaching the load □ Proximity hazards, obstructions, path of load
□ Overturning/load integrity/need for tag lines □ Working under suspended loads
□ Suitability and condition of Lifting Equipment to be □ Access and emergency escape routes
used □ Experience, competence and training of
□ Initial and final load positions and how it will get personnel
there □ Number of personnel required for task
□ Lifting over live equipment □ Pre-use Inspection of equipment by operator
□ Number and duration of lift(s) □ Visibility of the load
□ Conflicting tasks in area
Task Details (Step by Step)
Method(s) of Communications to be used: Radio □ Verbal □ Hand Signals

Steps taken to eliminate danger to personnel involved and others:

De-brief and learning points:

Planned by:
Position: Signature:
Date:
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Pre-Lift Toolbox Talk

Team members
Name Position Signature

10 Questions for a Safe Lift

# Control questions: Yes No


1 Is everyone aware of and do they fully understand the lifting and hoisting procedures
applicable to the lift?
2 Has everyone attended the toolbox talk?
3 Has a pre-inspection of the Lifting Equipment been carried out and are the Lifting
Accessories tagged or marked with: Safe Working Load, unique Identification Number,
valid certification date?
4 Are all safety devices working?
5 Does everyone know the Person-in-Charge of the lift?
6 Is everyone competent and aware of his tasks?
7 Is there a current Lift Plan and JHA and does everybody understand the job and
precautions?
8 Does everyone know the environmental limits (e.g. maximum permissible wind speed)
for the lift?
9 Is the lift area controlled and is everyone clear if the load falls or swings?
10 Are signaling methods and communication agreed and clear to you?
Job Hazard Analysis and Pre-job induction was conducted by Person Responsible for Job Conduction:

Position Name:

Signature: Date:

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Appendix 3: Three Level Lifting Equipment Management System

Appendix 4: Heavy Equipment Blacklist / Register

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