Overview of the Code of Practice for Safe Lifting Operations in the Workplace. Crane Safety 29 th September 2011

Transcription

1 Overview of the Code of Practice for Safe Lifting in the Workplace Crane Safety 29 th September 2011 Yeo Kim Hock Chairman Working Group CP for Safe Lifting in the Workplace 1/36

2 Preamble A good Code of Practice should be by the industry, and for the industry A Code, is for Use, based on consensus and availability of Technology & Knowledge. Outcomes, it delivers 3 things: - improvement in Workplace Safety and Health - increase Productivity, and - complying with Regulations

3 Working Group Composition Participation by all stakeholders, including manufacturers, suppliers, owners and users. Members identified by WSH Council office together with MOM (Spec) and Chairman of National Crane Safety Taskforce, Mr Tan Wee Seng Collectively the WG has more that 150 years of experience on lifting work The WG held its 1 st meeting on the 17 June 2010.

4 Working Group Composition Acknowledgement Mr Yeo Kim Hock (Chairman) - Gammon Construction Limited, Singapore Branch Mr Jason Heng - Tiong Woon Crane & Transport Pte Ltd Mr Ong Yong Seng - Shimizu Corporation Mr Michael George Hoyle (Mick) - Consultant to Exxon Mobil Asia Pacific Pte Ltd Mr Ah Singh Gill - Hiap Tong Crane & Transport Pte Ltd Mr Jacques (Jack) Hansoul - Arcomet Asia Pte Ltd Mr Liew Chern Yean - Wong Fong Engineering Works (1988) Pte Ltd Mr K.C.Foong - MHE-Demag (S) Pte Ltd Mr Ishak Ahmad Rosdi - Jacobs Engineering Singapore Pte Ltd Er. Theresa Liew (MOM) Mr Chia Chee Yong (MOM) Mr Davian Chiew (MOM) Mr Ng Jui Yong (MOM) Mr Silas Sng (WSHC) Mr Han Kin Sew (WSHC)

5 Targeted Timeline Apr/10 May/10 Jun/10 June/11 July /11 July/Aug /11 AUG 2011 contents development June st WG meeting on 17 June to confirm TOR, & table of contents for CP July 2011 Organise consultation session if necessary WG meetings to resolve comments, make amendments etc 5 Aug 2010 Available to industry in soft / hard copies with other publications in Safe Lifting KIT Apr - May 2010 Identify WG Chairman Identify WG experts (8 to 10) Propose SCOPE with Chairman Prepare TOR of WG Setting up Project Office etc 17 June 2011 Release for public consultation Concurrently seek NCS TF approval 13 July 2011 Submit to Publication for print-edit Publication etc

6 Terms of Reference To develop a Code of Practice (CP) for Safe Lifting that sets out a structured approach to ensure that lifting operations are systematically planned and carried out safely. Examples of key documents such as lift plans and checklists shall be included in the Code. Note: The CP will replace the current TA for Safe Operation of Lifting

7 Systematic Guidance Approach : Addressing the planning and implementation of safe lifting operations at all workplaces where lifting is required. Identification of operational factors that may affect safe lifting operations Development of a to better manage safe lifting operations Development of complementary and supplementary collaterals on safe lifting operations

8 The Product - CP Other collaterals supplementing / complementing the CP include: a. Guidebook for Lifting Supervisors b. Crane Operator's Handbook c. Riggers and Signalman's Handbook d. Posters

9 Contents of the CP Preface 1. Section 1: 2. Section 2: Factors affecting safe lifting operations 3. Section 3: 4. Section 4: 5. Section 5: Personnel roles and responsibilities 6. Section 6: Emergency and contingency planning 7. Appendix 1 Sample lifting plan / permit-to-work 8. Appendix 2 Sample checklist for mobile / crawler crane 9. Appendix 3 Sample checklist for tower crane 10. Appendix 4 Sample checklist for electric overhead traveling crane 11. Appendix 5 Sample checklist for lorry crane 12. Acknowledgement

10 Application Applicable: - to all work activities involving lifting equipment such as: mobile, crawler, tower, overhead travelling cranes, portal cranes, jib cranes and lorry crane/loader etc, excluding specialised lifting operations on floating docks and barges Provides guidance on: Identification of operational factors that may affect safe lifting operations. Development of a to better manage safe lifting operations. Normative References: - Lists of legislative and SS/ CP references - Publications in the Safe Lifting Kit

11 Purpose 4 Purpose developed to provide guidance on how to conduct lifting operations safely. highlights factors that need to be considered during the planning and execution introduces the as a systematic approach towards planning a lift. outlines the roles and responsibilities of those involved in a lifting operation. aimed at practitioners who are involved in lifting operations supervisors of those personnel in the lifting team.

12 Purpose 3 Purpose It is intended to provide examples of best practices, not meant to be prescriptive or imply that there is only one way of doing things, nor is it intended to replace or take precedence over recommendations, policies and procedures judged as safe as or safer than those given herein. use the CP as the preferred standard and continue to find ways to exceed and improve upon the practices detailed within. Note: This CP will replace the Technical Advisory for Safe Operation of Lifting published by WSH Council in May 2009

13 Purpose 2 Purpose - Prepare based on the collective experience from past accidents as well as good practices in safe lifting operation. - Provides practical guidance for the practitioner in the planning and execution of a lifting operation. - Not intended to provide the technical details on any specific lifting equipment & recommended that the manufacturer or supplier be consulted when more technical details are required.

14 Purpose 1 Purpose Regulatory Requirements - Develop to help stakeholders fulfill their statutory obligations under the Act in order to achieve a higher objective of ensuring safe lifting operation. - Complements the existing Singapore Standards and Code of Practices that had been developed on safe use of lifting equipment.

15 Addressing the planning and implementation of safe lifting operations at all workplaces where lifting is required. Identification of operational factors that may affect safe lifting operations Development of a to better manage safe lifting operations

16 The 5 M Model General: There are many factors that can affect a lifting operation. They are classified into: Machine Material Medium Man Method Where more details are needed, users are advised to refer to the operating or maintenance manuals or to the supplier or manufacturer of the equipment.

17 Routine Vs Non Routine Lift General: Routine Vs Non Routine Lift Define routine and non routine lift A misnomer perception of the categories of lift All categories of lift should warrant the same level of safety considerations

18 The 5 M- Machine Machine: Selection and integrity of the equipment to perform the job Sizing of the lifting equipment: Adequate lifting capacity and sufficient reach. Maintenance of the lifting equipment: Ensure structural stability Wire ropes:- Choose correct type and be properly maintained (lubricated) to prevent the ropes from snapping during operation. Braking mechanism:- Failure of the brakes would result in an unintended free fall of the suspended load. Safety devices:- Ensure safety devices are functioning properly and should never be by-passed in normal operation.

19 The 5 M- Material/ Load Material: Load that is intended to be lifted Weight most important parameter -must be ascertain to prevent overloading. It is safer to err on the side of caution and estimate a heavier weight than to assume a lighter one. Centre of Gravity (CG) critical to maintain the CG of the load directly beneath the load-line i.e. hook. When in doubt, it is advisable to consult an engineer. Method of rigging are well established in the industry. objective to ensure the load is stable, secure and balance throughout the lifting operation. Wt? Wt? CG

20 The 5 M- Medium Medium: acronym GOLDEN Ground the setup of the lifting equipment at a specific location. ensure that the ground is level and has sufficient bearing capacity. Obstacles temporary installations -nearby building, MRT tracks, overhead power lines, bridges or underground utilities / pipelines. Lighting condition the adequacy of the lighting condition- particularly during night operation Demarcation the zone of operation -demarcated to prevent persons from entering into zone unintentionally. Environment - weather conditions (heavy rain, haze or glaze, wind speed, thunderstorms, lightning) which impact the visibility of the lifting crew. advisable to stop all lifting operations when the weather condition deteriorates.

21 CP for Safe Lifting in the Workplace The 5 M- Man Man: Competency -Roles It is paramount that personnel involved is adequately trained and competent to carry out his duties properly. Fit for duty competency ability to read load charts the fitness of the personnel, existing medical conditions or length of working hours adversely affect his ability to discharge his duties must be considered. Roles and Responsibility All Personnel Empowerment to stop work if the operation is or has become unsafe. Communications communication devices such as radio walkie-talkie or application of standard hand signals and ensuring common understanding between members of the lifting crew.

22 The 5 M- Method 3 Method: and procedure to be adopted Some important factors along the life-cycle of a lifting operation are: Knowing the weight of the load and the load radius Securing the load using appropriate lifting gears such as slings, nets or receptacle Conducting a test lift to ensure stability and no overloading? Maintaining the centre of gravity (CG) of the load directly beneath the load-line i.e. the hook Stability of the suspended load during movement / slewing of the crane? Lowering / releasing of the suspended load CG

23 The 5 M- Method 2 Method: It is critical to note that; No lifting equipment or lifting gear shall be loaded beyond its safe working load except by an authorized examiner or an inspector for the purpose of testing such items.

24 The 5 M- Method 1 Overloading? OUTCOME!

25 Risk Management General mandatory to conduct a risk assessment on the safety and health risks posed to any person who may be affected by the lifting operation in the workplace. In order to help contractors discharge their duties and put in place a system to ensure safe lifting operation, a that harmonised the requirements for Risk Assessment and Permit-To-Work is recommended.

26 Risk Assessment / Permit To Work Risk Assessments and Permit to Work The 3 basic steps to risk assessment:- Hazard Identification - involves identifying the hazards associated with each work activity and type of potential accidents/incidents that can result from the hazards. Risk Evaluation - the process of estimating the risk levels of the identified hazards in terms of the severity of any injuries / damage if an accident were to occur and the likelihood of the occurrence. Risk Control - identifying appropriate risk controls measures so as to reduce the risk level to an acceptable level.

27 Objectives The primary objective of the is to facilitate common understanding amongst the lifting crew for a safe outcome. The underlying principle is that all foreseeable risks are assessed and eliminated / mitigated. The suggested template addressed key factors affecting safe lifting operations are: Details of the load; Details of the lifting equipment / lifting gears used; Means of communications; Personnel involved in the lifting operation; Physical and environmental considerations; Sequence / special precautions; Sketch of the zone of operation.

28 vis-à-vis RA & PTW Harmonisation of the vis-à-vis Risk Assessment and Permit-To-Work A risk assessment for lifting operation would typically specify control measures such as; appointment of competent personnel, usage of appropriately maintained lifting gears or demarcation of the lifting zone. These are needful and useful assessment, and should take into account the physical environment. The and the Permit-To-Work system are actually part of the Risk Control stage of the Risk Assessment process. A proper / Permit-To-Work serves as a means of verifying that the necessary control measures have indeed been taken. PTW Risk Assessment

29 Review Changes to s- Review of the Changes to the type and capacity of lifting equipment used. Changes to the sequence of operations. Changes requiring reconfiguration of the crane (boom/jib length, outrigger beam length reduction, parts of hoist line, etc). Changes in the rigging details which could result in a reduction in rigging strength or significant increase in rigging weight. Changes in surrounding environment such as sudden presence of a temporary structure obstructing the operation. Changes in the weather and environmental conditions which have an adverse impact to the lifting operation. Changes to safety-critical personnel.

30 Selection and Maintenance of Lifting Provides guidance for the selection, maintenance and other aspect of the lifting equipment. Selection of Positioning and Installation Identification of Lifting Pre-Use Checks

31 Selection of Selection of An equipment assessment must be completed as part of the risk assessment. Objective-to identify the hazards and assess the risks associated with the equipment for the foreseeable range of lifting operations The equipment assessment shall consider, but not necessarily be limited to the followings: Is the equipment designed for this intended type of lifting operation? What is the age of the lifting equipment? Was there any authorised modifications made to the equipment? What are the dismantling and assembly process? How are components of the lifting equipment transported to site for assembly? What type of pre-erection examination or Non-Destructive Testing (NDT) is required? How is the lifting equipment controlled e.g. via pendant or within the operator cabin? What are the access and egress for the operator to reach the cabin? What are the dismantling and storage requirements? What transportation methods to use for continued integrity?

32 Positioning & Installation Positioning and Installation Lifting equipment must be positioned or installed in order to:- Eliminate or reduce the risks to public or buildings in the immediate vicinity of the lifting operation Avoid having the load being manoeuvred over people. Avoid striking, trapping or crushing persons. Avoid striking any other structures such as buildings. Ensure that entrance and exit paths of existing passageways are not compromised by risks arising from the lifting operations. Avoid collision with other lifting equipment being used simultaneously. Provide suitable gates / barriers to prevent inappropriate / unsafe access to any hoist area. In general, whenever lifting equipment are disassembled and reassembled, they shall be subjected to a thorough re-inspection and load tested as per legal requirements by an Authorised Examiner to ensure integrity and stability of the equipment during the reassembly process.

33 Identification of Identification of Lifting Every lifting equipment and its component parts shall be identified with a visible marking including the safe working load (SWL). The markings serve the following purposes: Communicate clearly the maximum safe working load of the equipment. Communicate clearly the maximum number of persons it can carry if it is used for lifting people. Facilitate the identification of the equipment and its component including whether it is genuine and compatible with the equipment.

34 Safety and Warning Devices Lifting with variable Safe Working Load (SWL) Mobile crane equipped with a telescopic jib that can be raised or lowered. Tower cranes are also designed to have variable safe working load. Key principle, the closer the load is to the body of the crane, the higher will be the safe working load of the equipment. Such lifting equipments must; equipped with a load radius indicator to indicate to the operator- the SWL of the crane at that configuration (load radius), provide a visual and audible warning to the operator should the load lifted be close to SWL, the crane operator must exercise extreme care whenever he lowers the jib or telescope the boom outwards with a load as this will lead to a reduction of the SWL and potentially overloading the crane.

35 Safety and Warning Devices Lifting with variable Safe Working Load (SWL) For lorry cranes, if the Load Radius Indicator is not feasible, equipped with fully hydraulic protection valves and pressure relief system to prevent crane overloading. Some modern cranes are designed such that a different load capacity chart will apply depending on whether the outriggers are fully extended or partially extended. Under such circumstances the operator must be fully aware of the configurations and make the necessary adjustment to the parameter settings of the indicator. Information about how changes to the configuration affect the SWL must be provided in the operator s cabin. They should not simply be kept in the office as this denies the operator critical information he may need to perform a certain lifting operation.

36 Conduct Pre-Use Check Pre-Use Checks The operators of lifting equipment and accessories shall perform a pre-use check in order to identify any faults in the equipment. This should be a daily check at the start of each shift. Refer to sample checklists available in the Appendix 2,3,4 and 5 Useful tools for crane setup/ or pre use checks. Recommended for mobile and crawler cranes to equip with measuring tape, calculator, spirit level gauge and caliper.

37 Contractor General Outlines the responsibilities for all personnel and entities that are involved in the lifting operation. Contractor to ensure the lifting operation is carried out safely, they shall ensure:- A safe system of work (SSW) is established and implemented. LIFTING PLAN/ PTW/ RA The worksite is physically safe for the lifting operation The lifting equipment to be used is properly maintained and duly certified in accordance with legislative requirements. The lifting operation has the necessary resources to carry out the lift safely Personnel deployed as part of the lifting team are suitably trained, competent and certified, and that they had been briefed on the lifting operation Only competent sub-contractors are used All accidents, near misses, equipment failure or damage are reported and recorded

38 Lifting Team Lifting Team The Lifting Team refers to the group of personnel that is appointed to be directly involved in the lifting operation. The key factors to consider in selecting a Lifting Team include: Competency - Only suitably trained and competent personnel should be deployed as part of the Lifting Team. Composition It is good practice to try to maintain the same group of individuals in a Lifting Team so that the trust and rapport among team members can be built up over time. Communication The Lifting Team must use a common language that all members can understand. Any miscommunications can result in accidents.

39 Lifting Supervisor Lifting Supervisor Appointed in writing by the contractor. All lifting operation must be supervised by the appointed lifting supervisor and shall:-. Co-ordinate all lifting activities in accordance with the lifting plan. Brief all lifting team members on the lifting plan, safe lifting procedure and risk assessment. Ensure that only registered crane operators, appointed riggers and appointed signalmen participate in any lifting operation involving the use of mobile and tower cranes. Ensure that the ground conditions are safe for any lifting operation to be performed. Be present during all lifting operations. Take suitable measures to rectify any unsafe conditions to ensure the lifting operation can be conducted safely.

40 CP for Safe Lifting in the Workplace Lifting Operator 2 Lifting Operator Most important personnel of the Lifting Team - controls the lifting equipment. Key competencies of the operator of mobile, crawler or tower cranes; ability to read and understand the load capacity chart, and to differentiate the Gross Capacity and Net Capacity of the lift.

41 Lifting Operator 1 Lifting Operator The appointed lifting equipment operator shall: Carry out the lifting operation in accordance with the. Inspect the lifting equipment prior to use to check for abnormalities. Check that load radius indicator and other safety devices are functioning properly. Ensure the ground is stable and the surrounding is free from any structures or materials Carry out lifting operation only when a lifting supervisor is present on site. Disengage from any manoeuvre that is dangerous Monitor environmental effects such as thunderstorm and strong wind Report any defects immediately to the lifting supervisor, and Record such defects in maintenance log book. Stop the lift whenever unsafe conditions occur and To check crane wire rope to ensure it is still within safe use.

42 Signalman 2 Signalmen The appointed signalmen shall:- Ensure the load is correctly rigged up prior to giving signals to commence the lift. Give correct and clear signals to the lifting equipment operator to manoeuvre the load safely from the point of lift to the destination. Ensure communications are maintained throughout the lift in accordance with the lifting plan. Ensure the lift is controlled throughout

43 Signalman 1 Signalmen The appointed signalmen shall:- Ensure that the immediate areas within the lift are clear of any hazards during manoeuvre. Maintain his / her position so as to ensure line of sight during the controlled phase of the lift and to ensure this position is free of danger. Refrain from handling load/rigging simultaneously when giving signal to the crane operator

44 Rigger 2 Riggers The appointed riggers shall ensure:- All slings, webbings, shackles and other lifting gears used to rig the load are; within the safe working load (SWL) of the lift, in good condition and duly certified. The load is rigged up in a such a manner that it is ; stable, balance (centre of gravity beneath the hook) and secure (i.e. no loose items)

45 Rigger 1 Riggers The appointed riggers shall ensure:- The lifting equipment operator has been informed of the weight of the load. 1 Tons Wt? Wt? Establish tag-lines to control the load as it is being manoeuvred. CG Any defects in the lifting gear/ rigging and materials are reported to the lifting supervisor.

46 Erection & Maintenance Erection and Maintenance of Lifting The integrity of the lifting equipment to perform its task is highly dependent on how well it is being erected and maintained. It is important that the contractor appoints a qualified and experienced mechanics. Safety and Warning Devices Adherence to manufacturer s specification it is critical that the lifting equipment is erected, altered or maintained in accordance with the specification by the manufacturer as laid out in the operational and maintenance manual. This includes using all genuine components. Competency of mechanics / erectors such personnel should be provided with training relevant to the type of lifting equipment that they are handling Record keeping A record of all preventive or corrective maintenance shall be kept. Any defects reported should also be recorded into the log book.

47 Documented Emergency Response Procedure General All Lifting shall have a documented Emergency Response Procedure (ERP) that covers all aspects of the operations. The ERP identifies in a clear and precise manner the requirements and actions to be carried out for any foreseeable emergency (with or without any casualty). These include: Toppling of the lifting equipment. Structural failure of the lifting equipment such as boom fracture. Dislodgement of the suspended load. Entanglement of load with nearby structures. Recovery of injured personnel in locations where access is limited such as within a tower crane.

48 Emergency Response Procedure Emergency Response Procedures The contractor shall develop and document an Emergency Response Procedures (ERP) for the lifting operation and must be communicated to all personnel involved in the lift and made available at prominent locations at the workplace. The ERP shall include but not be limited to:- Details of emergency personnel and their contacts including first-aiders. Emergency communication flow chart. Roles and of the emergency management team. Emergency Services contact details. Managing injured persons. Frequency of exercise and drill to be carried out

49 Appendix 1 Sample / Permit To Work Note: 1.This is only a sample / PTW, the content is by no mean comprehensive. Users would have to include key critical document and information such as load capacity chart, range diagram, rigging method, sling angle etc to ensure safe lifting operations. 2.Further guidance can be obtained from the following collaterals: a. Guidebook for Lifting Supervisors b. Crane Operator's Handbook c. Riggers and Signalman's Handbook

50 Appendix 2 Sample Checklist for Mobile/ Crawler Crane This checklist provides an overview of the basic requirements to be checked which would help to ensure that a mobile/ crawler crane is safe for use. Mobile/ crawler crane users should consult manufacturers, suppliers and owners to check on minimum requirements and address any concerns before using the equipment. These items in this checklist are non-exhaustive and users are recommended to make the necessary modification and customisation to suit your work processes and conditions at the workplace.

51 Appendix 3 Sample Checklist for Tower Crane This checklist provides an overview of the basic requirements to be checked which would help to ensure that a tower crane is safe for use. Tower crane users should consult manufacturers, suppliers and owners to check on minimum requirements and address any concerns before using the equipment. These items in this checklist are non-exhaustive and users are recommended to make the necessary modification and customisation to suit your work processes and conditions at the workplace.

52 Appendix 4 Sample Checklist for Electric O/T Crane This checklist provides an overview of the basic requirements to be checked which would help to ensure that an overhead travelling crane is safe for use. Overhead travelling crane users should consult manufacturers, suppliers and owners to check on minimum requirements and address any concerns before using the equipment. These items in this checklist are non-exhaustive and users are recommended to make the necessary modification and customisation to suit your work processes and conditions at the workplace.

53 Appendix 5 Sample Checklist for Lorry Crane This checklist provides an overview of the basic requirements to be checked which would help to ensure that a lorry crane is safe for use. Lorry crane users should consult manufacturers, suppliers and owners to check on minimum requirements and address any concerns before using the equipment. These items in this checklist are non-exhaustive and users are recommended to make the necessary modification and customisation to suit your work processes and conditions at the workplace.

54 In Conclusion Make Every Lifting SAFE

55 Thank You