CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 1 of 22

LIFTING PROCEDURE

Date Description Return Code

Revision

B 08/12/2021 ISSUE FOR APPROVAL

A 29/09/2021 ISSUE FOR APPROVAL 2
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 2 of 22

Table of Contents
1.0 PURPOSE 3
2.0 SCOPE 3
3.0 DEFINITIONS 3
4.0 REFERENCE 5
5.0 ROLES AND RESPONSIBILITIES 5
5.1 CONTRACTOR PROJECT MANAGER 5
5.2 CONTRACTOR CONSTRUCTION MANAGER 5
6.0 GENERAL REQUIREMENTS 5
6.1 SPECIFIC STANDARDS TO BE REFERENCED 5
6.2 CRANES 7
6.3 BARRICADES AROUND CRANES 7
6.4 GENERAL 7
6.5 PERMITS 8
6.6 LIFTING CHECKLIST 8
7.0 SUBMITTALS 8
7.1 RIGGING/LIFTING DRAWINGS 8
7.2 HEAVY HAUL DRAWING 9
8.0 CRANES 9
8.1 CRANE INSPECTIONS 9
8.2 CRANE OPERATORS 9
8.3 GENERAL 10
9.0 OUTRIGGERS 12
10.0 RIGGING EQUIPMENT AND HARDWARE 12
10.1TAG INSPECTION REQUIREMENTS 14
11.0 LIFTING LUGS 15
12.0 SIGNALS AND SIGNALMAN 16
13.0 CATERGORIES OF LIFTS 17
13.1NON CRITICAL LIFTS 17
13.2CRITICAL LIFTS 17
14.0 WORK NEAR OVERHEAD ELECTRICAL LINES AND HAZARDOUS PIPELINES 18
15.0 TRAVELLING WITH A LOAD 18
16.0 INSPECTIONS AND TESTS 19
16.1CRANES 19
16.2BELOW-THE-HOOK LIFTING DEVICES 20
16.3HOOKS 20
16.4LIFT LUGS AND APPENDICES 20
16.5SLINGS 21
17.0 LIFTING HAZARD 21
17.1HOIST LINE NOT PLUMB. 21
18.0 EXECUTION 22
19.0 APPENDICES 22
19.1LIFTING CHECKLIST 22
19.2CRITICAL LIFT CHECKLIST 22
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 3 of 22

1.0 PURPOSE

This procedure will be applied to all lifting operations realized on the site during all phases of the
Project.

The purpose of this document is to reduce the risk of personnel injury, property damage and
business interruption when it is necessary to conduct a lift using either mobile or a tower cranes.

The use of this procedure ensures proper planning, hazard assessment, authorization and safe
crane operating methods are performed.

2.0 SCOPE

This plan applies to all activities under the management of MIE in CIVIL STRUCTURE WORK
(Package A) and PIPING, MECHANICAL EQUIPMENT ERECTION, ELECTRICAL &
INSTRUMENTATION, INSULATION & PAINTING WORKS (Package B) FOR PROCESS AREA
FOR PHASE 1 (50 KTPA) FOR PROPOSED 200 KTPA NITRILE BUTADIENE RUBBER (NBR)
LATEX PLANT ON LOTS 2604,2605,2615 AND 2616, MUKIM TANJUNG DUABELAS, DAERAH
KUALA LANGAT, SELANGOR DARUL EHSAN (F44SL NBR LATEX PLANT PROJECT) FOR TOP
GLOVE SYNTHETIC RUBBER SDN BHD.

3.0 DEFINITIONS

COMPETENT A person who, because of knowledge, qualifications and experience,

PERSON in their assigned area of expertise is capable of Identifying existing and
predictable hazards; has authority to take prompt corrective action to
eliminate them.
CONTRACTOR MIE INDUSTRIAL SDN BHD
EMPLOYEE Any person engaged in activities for the benefit of the Project and who
receives payment, even on a temporary basis.
OWNER TOP GLOVE SYNTHETIC RUBBER SDN BHD
PROJECT TSR F44SL Project Phase 1
SUBCONTRACTOR means the person or persons, firm or company named as such in the
Subcontract Agreement, who has undertaken to execute the WORKS
under this SUBCONTRACT and includes the SUBCONTRACTOR's
legal or nominated representatives, personnel, successors,
SUBCONTRACTORs and permitted assignee.
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

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Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 4 of 22

Other definitions:

Anti-Two Block is a safety device which, when activated disengages all crane functions to avoid
two-blocking.

Authorized Crane Operator is a designation obtained by an operator. Authorization is granted

based on experience, training and/or certification.

Boom is a member hinged to the rotating superstructure and used for supporting the hoisting
tackle.

Boom Angle is the angle above or below the horizontal measure from the longitudinal axis of the
crane turntable.

Counterweight is any weight used to supplement the weight of the crane to provide additional
stability for lifting loads.

Critical Lift is a non-routine crane lift requiring detailed planning and additional or unusual
precautions. Critical lifts include, but are not limited to:

 Lifting more than 40 tonnes.

 Lifting over live or critical/sensitive process equipment or facility.
 Lifting load of weight more than 80% of rated capacity of the lifting equipment at the
specified working radius and boom angle as per the crane load chart.
 Lifting of special load such as structure, boiler and vessel.
 Tandem lifting using multiple cranes.
 Lifting at location less than the specified safety distance from live overhead power line.
 Lifting operation for testing purposes e.g. crane load test, integrity test of crane components
etc.
 Other lifting operation deemed as critical such as blind lift, lifting through hatches etc.

Dry Run is unloaded lift cycle test to ensure load clearances and boom reach will e adequate for
the critical lift.

Heavy Haul any equipment or material exceeding 30 tons whose overall dimensions exceed width
or length of transporter and or require specialist transportation, or over width or length for highways
plant access and requires clearances from regulatory authorities for vehicle movement. Or may
Impact upon road access for other road users.

Jib is an extension attached to the end of the boom to provide added boom length for lifting
specified loads. The job may be vertically in live with the boom or offset to various angles in the
vertical plane of the boom.
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Document Title LIFTING PROCEDURE

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Outriggers are extendible or fixed members attached to the crane base to support the crane
during a lift.

Two-Blocking is the condition in which the lower load blocks or sheaves assembly near the end of
the boom. This condition can cause crane damages and may cause the load to drop.

4.0 REFERENCE

F44SL-PHASE1-MIE2-HSE-PLN-0001_Project HSSE Plan

F44SL-PHASE1-IPMT-HSE-PRC-0001 F44SL Project PTW Procedure_Rev0
CLIENT’s F44SL 13 LIFE SAVING RULES
International Standard & Local regulations

5.0 ROLES AND RESPONSIBILITIES

5.1 CONTRACTOR PROJECT MANAGER

To ensure that the requirements of this Procedure are adhered to.

5.2 CONTRACTOR CONSTRUCTION MANAGER

To ensure that all CONTRACTOR EMPLOYEE and SUBCONTRACTORS adhere to the

requirements of this Procedure.

To take immediate corrective actions in case of unsafe situations noted during the site
walk around and inspections.

To refer to CONTRACTOR Project Manager.

6.0 GENERAL REQUIREMENTS

This procedure contains the operational requirements for cranes, lifting, hoisting, and rigging; All
work must be in accordance with Malaysian DOSH requirements, this procedure, the
requirements of its attachments and the permit to work system.

Prior to starting work, operations involving crane and rigging works will be assessed using the
JHA or equivalent. Both the JHA and Risk Assessment portions of the form are required for these
operations to ensure that all hazards associated with the work are identified, the likelihood and
severity are understood, and control measures are defined that will effectively reduce the risk.

6.1 SPECIFIC STANDARDS TO BE REFERENCED

CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

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The follow standards will be a used for reference to Cranes, Rigging and Lifting equipment
used on CONTRACTOR work fronts.

American Standards

 Specification for Offshore Pedestal Mounted Crane (2004) API 2C Operation and
Maintenance of Offshore Cranes (2007) API 2D Specification for Wire Rope (2004)
API P9A
 Recommended Practice on Application, Care and Use of Wire Rope for Oil Field
Service (1999) API RP 9B
 Inspection, Maintenance, Repair, and Remanufacture of Hoisting Equipment API
8B
 Mobile and Locomotive Crane ASME B 30.5
 Alloy-Steel Chain Slings, Wire Rope Slings, Metal Mesh Slings, Synthetic Webbing
Slings, Synthetic Round Slings (1999) ASME B 30.9
 Overhead Hoist (Underhung) (2003) ASME B30.16
 Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung
Hoist) (2006) ASME B30.17
 Manually Lever Operated Hoists (2005) ASME B30.21

British Standards:

The following are some of the Standards and Codes (latest Edition) that may be
applicable as deemed necessary:

 Code of Practice for Safe use of Cranes – General BS 7121 Part 1

 Code of Practice for Safe use of Cranes – Inspection, testing and Examination BS
7121 Part 2
 Code of Practice for Safe use of Cranes – Mobile Cranes BS 7121 Part 3
 Code of Practice for Safe use of Cranes – Tower Cranes BS 7121 Part 5
 Code of Practice for Safe use of Cranes – Offshore Cranes BS 7121 Part 11
 Power Driven Overhead Travelling Cranes, Semi-Goliath and Goliath Cranes for
General Use BS 466
 Code of practice for safe use of construction Hoists BS 7212
 High Pedestal or Portal Jib Cranes BS 2452
 Rules for Design of Cranes - Part 1: Classification, stress calculations and design
criteria for structures BS 2573-1
 The Design and Testing of Steel Overhead Runway Beam BS 2853
 Verification of Stability of Industrial Trucks Operating In Special Condition of
Stacking with Mast Tilted Forward BS 5778
 Steel Wire Ropes Slings-Safety-Slings for General Lifting Services (2003) BS EN
13414 Part 1
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 Steel Wire Ropes Slings-Safety-Specification for Information for Use and

Maintenance to be Provided by the Manufacturer (2003) BS EN 13414 Part 2
 Steel Wire Ropes Slings-Safety-Grommets and Cable-Laid Slings (2003) BS EN
13414 Part 3

6.2 CRANES

The following documentation (as a minimum) must be stored in the crane during
operation:

 Crane operators License and competency from DOSH.

 Completed pre-shift inspection (required to be completed daily by the operator)
 Inspection Report – Crane Work Area
 Operating manual
 Load chart
 Load cell calibration certificate (if available)
 Critical lift permit(s), and any associated rigging drawings or applicable
documentation

6.3 BARRICADES AROUND CRANES

Accessible areas within the swing radius of the rotating superstructure counterweight of a
crane must be barricaded and signage displayed to prevent employees from being struck
or crushed by the counterweight.

Accessible areas within the swing radius of the rotating superstructure or the rotating
superstructure counterweight of a crane will be barricaded to prevent personnel from
being struck or crushed.

6.4 GENERAL

 The crane operator, riggers, and signal persons must be trained, experienced, and
licensed for the operation of that specific make and model of crane.
 Each time a crane is moved into service, or to a new location, for a lift the operator
must conduct an inspection of the area in which the crane will be operating. Then
complete the daily checklist form.
 Entertainment headphones will not be worn by operators or any other person
during rigging and crane work.
 Employees will not be allowed to ride the headache ball, hook, block, or the load
being handled by the crane.
 Equipment must not be lubricated while the crane is in operation, unless the crane
is designed for safe lubrication during use and manufacturer’s guidelines are
followed.
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Document Title LIFTING PROCEDURE

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 Passengers will not ride in or on the crane unless it is specifically designed for
more than one passenger/operator. The crane will not be used for personnel
transportation or as a personnel carrier
 A tag or restraint line(s) will be used to control swinging of the load, unless the
tagline creates a greater hazard.
 A professional engineer must certify that the crane foundations and underlying soil
are adequate support for a tower crane with its maximum overturning movement.

6.5 PERMITS

A Permit To Work, must be issued prior to the commencement of any Crane lift.

CONTRACTOR and SUBCONTRACTOR is responsible for the appointment and training

of their Permit Requester that will complete documentation for a Lifting checklist or a
Critical Lift permit.

6.6 LIFTING CHECKLIST

Lifting checklists Form will be completed prior to all crane lifts. (This form is shown in
Appendix 1 to this procedure) CONTRACTOR and SUBCONTRACTOR is responsible for
the appointment and training of their riggers and crane operators that will complete the
Green Lift checklist form.

7.0 SUBMITTALS

7.1 LIFTING STUDY / PLAN

Lifting study/plan must be supplied for all lifts classified as “Critical Lifts” under the
descriptions

Lifting interference drawings must be required when critical lifts are being located these
drawings should show foundations and equipment that must be removed or not installed
until after a critical lift operation.

Lifting study shall include Plot Plans and Elevation Drawings that must be detailed and
comprehensive erection drawings that define all major elements of a heavy rigging
activity. The drawings must include the following as a minimum:

 Total weight to be lifted including load blocks and rigging gear

 A scale plan view showing the locations of lifting equipment, lifted items, and their
relationship with any potential obstructions
 A scale elevation view that shows the relationship and clearances between the lifting
equipment, lifted items, and potential obstructions
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

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 Lifting and tailing hook-ups, including shackle, sling, and spreader bar sizes, lengths,
and capacities
 A description of the configuration of the cranes indicating model number, boom length,
boom type, auxiliary counterweights, parts of load line, jib, length, type, offset, etc.
 Crane capacities based on the actual working radius and the crane configuration
 A description of the placement of crane mats, deadmen, guy lines, earth fill, or any
other items required for the safe execution of the lift
 A description of any “holds” that must be placed on existing plant structures or
equipment that would interfere with the lift plan.
 A detailed written description that adequately describes any part of the lift not made
clear by the drawings.

7.2 HEAVY HAUL DRAWING

A Heavy Haul drawing must be provided for all equipment transportation classified as a
“critical lift”

A Heavy Haul Drawing must contain the following minimum information:

 Equipment to be used in transporting and handling each item, including equipment
capacities
 Method of securing load to the heavy haul equipment
 Axle loads and spacing

8.0 CRANES

8.1 CRANE INSPECTIONS

In Malaysia; to enforce this directive, the DOSH will use provision 26(1) of the Factories
and Machinery (Notification, Certificate of Fitness and Inspection) Regulations1970 to
stipulate that Hoisting machinery shall be inspected.
 The regular interval shall be 15 months

8.2 CRANE OPERATORS

In Malaysia; to enforce this directive, the DOSH will use provision 26(1) of the Factories
and Machinery (Notification, Certificate of Fitness and Inspection) Regulations1970 to
stipulate that all the said cranes must be operated by certificated operators.

 Tower crane (Menara)

 Mobile crane (Bergerak)
 Derrick crane (Derik)
 Crane operator shall be reassessed every 3 years.
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 Crane operator of age 40 years old and below shall undergo full medical check- up
minimum every 2 years. Crane operator above the age of 40 years shall undergo full
medical check-up annually by qualified OSH medical practitioner
 Mobile Crane Operator shall obtain valid driving license from the national and/or
regulatory bodies. Note: for Malaysia; Class H driving license.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

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8.3 GENERAL

Lattice boom and hydraulic mobile cranes (except articulating boom cranes) must be
equipped with the following:

 Boom angle or radius indicator

 Drum rotation indicator
 A means for the operator to determine the levelness of the crane
 Anti-two block device, two-block damage prevention, or two-block warning device

Jibs for crawler, locomotive, and truck cranes must have positive stops to prevent their
movement of more than 5 degrees above the straight line of the jib and boom on
conventional-type crane booms. The use of cable-type belly slings does not constitute
compliance with this requirement.

Cranes with variable angle booms must be equipped with a boom angle indicator, readily
visible to the operator.

Crane operators must have a thorough understanding of all operational characteristics

and capabilities and safety rules and regulations pertaining to the different types of
cranes, including “cherry pickers” and boom trucks.

Load capacity charts indicating all pertinent configuration information for any crane must
be with the crane and available at all times. Specialty load capacity charts and charts
developed for a particular crane must show the configuration and crane serial number on
the chart. This information must correspond with the configuration and serial number of
the crane it is being applied with.

For all stationary-lifting operations, the total load lifted, including all deductions may not
exceed 95 percent of the crane’s load chart for the actual configuration and lift radius.
Under extraordinary circumstances subject to prior review and acceptance by the lifting
supervisor, this limitation may be exceeded.

Note: The operator must test the brakes each time a load that is 90 percent or more of the
maximum line pull is handled by lifting the load a few inches and applying the brakes. In
duty cycle and repetitive lifts where each load is 90 percent or more of the maximum line
pull, this requirement applies to the first lift only.

A tape measure must be used to layout the radius. The boom angle indicator will only be
used as a reference.

The operator must be instructed to engage the boom dog and release it only when
booming down is required.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

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Lifts must not be made in winds that exceed the manufacturer’s recommendation, or in
winds 32 kph (20 mph) or greater

Hydraulic truck cranes must not be used to walk loads from one place to another unless
approved by lifting supervisor with the following conditions met:

 The crane is moving over firm level ground or the outriggers are extended and the
floats are positioned close to the ground
 The boom is positioned in the pick-and-carry position
 Load capacities, boom length, travel speed, and tire inflation pressures are in
accordance with the manufacturer’s recommendations

For all lifting operations where the crane is traveling with the load, the total lifted load,
including all deductions, must not exceed 90 percent of the crane’s load chart for the
actual configuration and lift radius.
 Under extraordinary circumstances and subject to prior review and acceptance by
the CONTRACTOR Lifting Supervisor, this limitation may be exceeded.
 The minimum clearance between the load and the crane boom, or any other
critical structural component, will not be less than 1 meter while the crane is
traveling.
 Before traveling with a load, the load must be tied back or secured in such a way
that swinging of the load is controlled or minimized.

The rated capacities of each crane used in multiple-crane lifts (exclusive of a tailing crane)
must be reduced a minimum of 30 percent unless one of the following conditions are met:

 An equalizing beam, or other approved method of load equalization, is used.

 It can be determined by calculations, or demonstrated, that the transfer of load
from one crane to another during any operation of the erection process cannot
occur to any appreciable extent.
 It can be determined by calculations, or demonstrated by safe and reliable means,
that the monitoring of the respective loads and the control of each crane during the
erection process must provide a fail-safe means for performing the lift safely.

Crane mats, or other acceptable load-spreading devices, will be used for all lifts. They are
mandatory when lifts exceed 85 percent of the crane’s chart capacity when stationary, or
75 percent of chart capacity when traveling, except under one of the following conditions:

 It can be determined by calculations, or demonstrated, that the bearing pressure of

the crane acting on the crane pad without mats must not exceed the allowable
bearing capacity of the soil.
 Conditions of the soil are such that mats become mandatory during a lift of any
magnitude.
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 The lift is of such a critical or sensitive nature that mats become mandatory during
a lift of any magnitude.

Crane Jibs – A jib or fly jib on any crane must be used only if the following requirements
are met:
 Application to the lifting supervisor for use of the jib is submitted with the request
for an inspection and the subsequent inspection finds it structurally sound
 The crane manufacturer’s specifications for the jib are on site and followed
 A load/capacity chart for the jib is available and with the crane
 Cranes equipped with weight or load indicators incorporate the jib operation
 Crane operator is certified to be knowledgeable/proficient on jib
assembly/disassembly and operation

9.0 OUTRIGGERS

Crane outriggers must be fully extended or deployed in accordance with load-rating chart
specifications and set to remove the machine weight from wheels before the boom is moved from
its travel position or any lifting operation begins.

Blocking or load spreaders must be used under each outrigger float regardless if the crane is
being set up on soil or concrete.

Blocking or load spreaders under outriggers must be sized to provide at least a minimum of 400
percent more load-bearing area than the outrigger floats provide and to resist the resulting
bending stresses. Exception: If it can be determined by calculations, or demonstrated by safe and
reliable means, that the bearing pressure of the crane floats acting with the load spreaders of the
reduced size must not exceed the allowable bearing capacity of the ground.

When crane mats are used, they must be made of hardwood timbers a minimum of 200mm thick
and arranged to spread the load to the soil. In conditions of poor soil, more than one layer of
crane mats may be required to spread the load sufficiently. (Mats made of other materials may be
used if prior acceptance is obtained from the lifting supervisor.

10.0 RIGGING EQUIPMENT AND HARDWARE

Placement and use of all transportation, lifting, and rigging equipment must be in accordance with
manufacturer’s specifications and industry standards. In no case must such equipment be used
beyond the safe limits imposed by the manufacturers or other applicable safety standards.

Transportation, lifting, and rigging equipment must not be modified or altered without the
manufacturers’ written approval. All such modifications must be in accordance with the
manufacturer’s specifications or guidelines.
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Under special circumstances, and with the approval of the manufacturer CONTRACTOR’S lifting
supervisor, equipment may be re-rated, or modified and re-rated.

 If manufacturer’s specifications are not available, the limitations assigned to the

equipment must be based on the determination of a qualified engineer competent in this
field. Such determination must be appropriately documented and recorded.
 Re-rated equipment must be given a dynamic load test using a test load of 125 percent of
the lift weight. Except as otherwise directed, a dynamic load test must include the raising,
traversing, and lowering of the load over the full range of motion of the actual lift.

All custom-designed rigging equipment, such as spreader bars, beams, links, and any other
device that carries all or part of the load being lifted, must be:

 Designed to meet ASME B30.20 allowable design stresses, using 1/3 of yield or AISC
allowable stresses with a load factor of 1.8 will meet this requirement.
 Load tested in accordance with ASME B30.20, to 125 percent of the rated load and test
reports kept on record.
 Marked in accordance with ASME B30.20 with manufacturer’s name and address,
identification number, weight, and rated load.

All shackles must be in good condition, with the capacity permanently indicated on the shackle.
All slings must be in good condition, load-tested as required in ASME B30.9, and identified with a
permanent identification to show:

 Name or trademark of manufacturer

 Rated loads for the type(s) of hitch(es) used and the angle upon which it is based
 Diameter or size and length
 Types and grades of material used
 For synthetic materials, the manufacturer’s code or stock number

If one wire rope of a set (such as pendant lines) will require replacement, the entire set of ropes
must be replaced. Wire rope with one or more of the following defects will be removed or replaced
immediately:

 Kinking, crushing, bird-caging, or any other damage resulting in distortion of the rope
structure
 Evidence of heat damage from any cause

Protect rigging and lashing from damage by softeners or other means.

Protect nylon, wire rope, or other slings subject to damage by sharp edges during the lift.
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Do not use chains or ropes of a come-along or chain fall as chokers. Chain Falls may be utilized
in a rigging hook up as long as manufacturer’s instructions for use are followed.

Cover and secure buckets, barrels, and tubs used to lift smaller objects during lifting to prevent
their contents from spilling.

Do not use sheet dogs (clamps) to lift sheet goods (such as sheet metal and boiler siding) or
other objects of a sheet nature without management/supervision approval.

Store rigging equipment and protect from the elements when not performing work activities.

The capacity or size of the shackle or lifting link must not be less than that specified on the lift
drawings or plans.

Unless specified otherwise, pin hole diameters will be at least 90 percent of the diameter of the
pin hole. For pin diameters smaller than 90 percent the lifting lug must be reviewed for the effect
of using a small pin.

Exposed or unprotected carbon steel slings and rigging hardware must not be permitted to come
into contact with stainless steel or nonferrous plant equipment except at the pin holes of lifting
lugs.

Synthetic fibre slings (web or round) must not be used to choke or wrap around structural steel or
in any other application where they could be exposed to sharp edges. CONTRACTOR Lifting
Supervisor or Engineer must approve any use of a synthetic fibre sling that requires the use of
padding to protect the sling.

Temporary wood softeners, or other approved alternate, must be used to protect plant equipment
from damage due to concentrated bearing points and movement of rigging hardware. Finish
painted surfaces are to be further protected from discoloration, scratches, gouges, and other
effects of direct contact with slings and rigging hardware.

Rigging equipment (such as ropes, slings, shackles, lifting beams, and hooks) must be visually
inspected before each major lift. Unacceptable rigging equipment must be removed from the site.

10.1 TAG INSPECTION REQUIREMENTS

All rigging and lifting equipment shall be inspected and tagged on a quarterly basis (every 3
months) in accordance with the following colour code system. Tags must show the date of tag
application. Day, Month and Year.

The CONTRACTOR and SUBCONTRACTOR shall be responsible for the inspection and tagging
process of all Cranes, Lifting and rigging equipment under their ownership or hire.
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Period Colour
January to March Yellow
April to June Blue
July to September Green
October to December Red
* Any damaged or defected items shall be removed from site by responsible party.
Inspection and tagging will be completed by a Competent and Qualified Rigger.

To assist in inspection and tagging time frames, inspection and tagging may be started 14 days
before the First day of each quarterly date and may continue 14 days after the end date. Any
equipment not correctly tagged outside of this process will be removed from service tagged “Out
of Service” and shall not be used until inspected and correctly tagged

11.0 LIFTING LUGS

Note: All weights are in metric tons

CONTRACTOR engineer must design or review the lifting lugs for all equipment over 10 tons, or
any equipment that will be upended during erection causing the load to the lug(s) to be applied in
more than one direction.

Review of the existing pre- fitted lifting lugs for equipment equal to or below 10 tons must be the
responsibility of the CONTRACTOR’s Lifting Supervisor.

All custom-designed lifting lugs must be designed to meet ASME B30.20 safety requirements and
in accordance to ASME BTH-1 using a Design Category B unless the designer can justify a
Design Category A. Using 1/3 of yield or AISC allowable stresses with a load factor of 1.8 will
meet the BTH-1 Category B requirement, except for pin bearing, which should conservatively be
based on the BTH-1 formula for allowable bearing stress.

The necessary rigging gear must be provided to use all designated lifting points on fabricated
equipment as shown on the drawings, unless directed otherwise by the supplier or the equipment
engineer.

Only lift lugs, which appear on approved drawings, must be used.

Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, etc., or other such
attachments must not be used.

Lifting attachments must only be used in a manner consistent with the design of the attachment.
In general, flat, unstiffened plate lugs must only be loaded in the strong direction of the lug.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 17 of 22

Lifting attachments used for overhead lifting, that are bolted on or otherwise attached so that they
are not an integral part of the object being lifted, must be proof-tested to 125 percent of the rated
load and marked to indicate the safe lifting loads.
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 18 of 22

12.0 SIGNALS AND SIGNALMAN

Hand signals for signalling the operator are those prescribed by the ANSI standard applicable to
each crane or as per local Malaysian state or Government body requirements.

Only one person will assume signal duties and no other person will signal the operator during the
lift.

Exceptions:
 A person giving an emergency stop signal
 When 2 signal persons are needed for lifts (One must be assigned as Lead signalmen)

Example of common hand signals

 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 19 of 22

13.0 CATERGORIES OF LIFTS

13.1 NON-CRITICAL LIFTS

 In general, a lift that is under 15 tons and less than 75 percent of the rated capacity
of a crane for the configuration of the lift.
 Contractor's Rigging and Lifting Specialist or other authorized personnel site
representative will review all Lift Certificate for noncritical lifts.
 A Lift Certificate is required for All crane lifts.
 Responsible personnel for a noncritical lift must be a crane operator and field
rigger.

13.2 CRITICAL LIFTS

Critical lifts include, but are not limited to:

 Lifting more than 40 tonnes.

 Lifting over live or critical/sensitive process equipment or facility.
 Lifting load of weight more than 80% of rated capacity of the lifting equipment at
the specified working radius and boom angle as per the crane load chart.
 Lifting of special load such as structure, boiler and vessel.
 Tandem lifting using multiple cranes.
 Lifting at location less than the specified safety distance from live overhead power
line.
 Lifting operation for testing purposes e.g. crane load test, integrity test of crane
components etc.
 Other lifting operation deemed as critical such as blind lift, lifting through hatches
etc.

Before a critical lift, a Critical Lifting Plan must be developed by rigging supervisor and the
required approvals obtained. A copy of the permit and any associated rigging drawings
must be placed in the cab of the crane, with the original filed at the site.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 20 of 22

 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 21 of 22

14.0 WORK NEAR OVERHEAD ELECTRICAL LINES AND HAZARDOUS PIPELINES

Any activity involving a crane (including assembly and disassembly) where there is a potential for
any part to come with 10 meters (33 feet) of an energized power line requires special controls to
be developed and implemented

15.0 TRAVELLING WITH A LOAD

When travelling with a load, the following requirements will be implemented:

 A competent person must supervise the operation.

 Determines if it is necessary to reduce rated capacity.
 Makes determinations regarding load position, boom location, ground support, travel route,
overhead obstructions, and speed of movement necessary to ensure safety.
 The determinations of the Competent Person are implemented.
 For equipment with tires, the tire pressure specified by the manufacturer is maintained.
 Rotational speed of the equipment must be such that the load does not swing out beyond the
radius at which it can be controlled.
 A tag or restraint line must be used — as appropriate/necessary— to prevent rotation of the
load that would be hazardous.
 The brakes must be adjusted in accordance with the manufacturer procedures to prevent
unintended movement.
 The operator must obey a stop (or emergency stop) signal, irrespective of who gives it.

16.0 INSPECTIONS AND TESTS

16.1 CRANES

When brought onto Project/site, each crane shall have a certification copy of a
CONTRACTOR approved third party inspection or inspected by appointed by
CONTRACTOR. The documentation, insurance documents and operator certification and
license must be presented to CONTRACTOR rigging supervisor for review and inspection.

As a minimum, cranes shall be checked for:

 structural damage and/or modifications;

 hydraulic leaks;
 broken wires in running, rotation resistant, and standing ropes and correct end
termination;
 structural integrity of the load block and the overhaul ball;
 correct spooling of the hoist lines on all drums;
 Tire inflation and wear; and
 Correct counterweight configuration as recommended by the manufacturer.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 22 of 22

Load and Functional Testing

A long radius, full-capacity load test shall be performed by SUBCONTRACTOR or Sub

contractor third party and witnessed by CONTRACTOR HSE and or an approved Rigging
Supervisor to verify that:

 Load indicating devices, if installed, are working properly and the accuracy of the load
indicator is not less than 100% or more than 110% of the actual load.
 Overload function for each drum is working properly and will disengage when the
maximum radius is reached for the load being lifted (applicable only if the crane is
equipped with a Load Moment System).
 Boom will telescope in and out, and boom up and down under a capacity load. The
telescoping function is not required if the manufacturer prohibits its use for the
particular boom length and boom angle being used.
 Brakes release smoothly and are capable of holding the load.
 Crane is stable at the maximum operating radius.
 Crane can perform designed multi-function operations, i.e. swing, hoist and boom, etc.
 Operator is competent and familiar with the machine, including the safety systems and
is fully capable of reading and understanding the load charts.
 The long radius load test shall be performed by picking a known load in a direction or
area that provides minimum risk and booming out while holding the load 0.3 m (1 ft)
above grade until the crane reaches maximum capacity and then booming back to the
original position.
 For any major repair, load test & revalidation shall be conducted by DOSH authorized /
registered contractor.
 The test weights used in the above testing shall be certified to plus or minus 5%.
 Both the load block on the main hoist line and the overhaul ball on the whip line shall
be raised to maximum height to ensure that the anti-two-block device will either warn
the operator of the limit of hoisting, or will kick out the hoisting function.

16.2 BELOW-THE-HOOK LIFTING DEVICES

All below-the-hook lifting devices should have a certificate showing that they have been
load tested to 125% of their rated load as specified in ASME/ANSI B30.20.

If the load test certificate described above is not available, and with Contractor rigging
supervisor acceptance, calculations showing that the device has been designed to meet
the design requirements of ASME/ANSI B30.20 may be substituted for the test certificate.

16.3 HOOKS

Crane hooks shall be made from either forgings or castings (steel or alloy) that have been
quenched and tempered.
CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 23 of 22

A proof load certificate is required for all forged crane hooks over 100 tons capacity and
for all cast crane hooks regardless of capacity.

The test certificate or documentation specified above shall be provided for each hook
stating the SWL (Safe Working Load) as specified by the manufacturer, and that the hook
has been proof loaded to a minimum of 110% of the rated load of the hook. The hook shall
be stamped or otherwise identified and be traceable to the certification / documentation.

16.4 LIFT LUGS AND APPENDICES

Lift lugs shall be inspected by the engineering and/or QC group prior to the lift. The
inspection should include the following:
 The size and quantity of all components shall be checked, making sure that all
parts, such as gussets and reinforcing plates have been installed according to
drawings.
 The location and orientation of lifting Appendices shall be checked for
conformance to drawings and specifications.
 Appendix welds for lifting lugs shall be inspected for conformance to drawings.
 Any damage or non-conformity noted shall be brought to the attention of the
CONTRACTOR rigging supervisor

16.5 SLINGS

All slings shall have a test certificate showing that they have been proof tested and stating
the safe working load, size, and identification.

All slings shall be regularly inspected in accordance with the requirements of ASME/ANSI
B30.9 for frequent and periodic inspections and removed from the job Project/site if they
fail to meet the requirements of ASME/ANSI B30.9-2.8.3.

The following guidelines are recommended for the safe use of round slings:
 Check and ensure round slings are not defective prior to any lifting operations
 Ensure the round sling engages correctly with fittings and the lifting hook.
 Ensure that smooth radii are formed which allow the sling to naturally flattened
under load
 Ensure that round slings are not twisted or crossed and fittings are not over
crowded
 Ensure there is no weakening or softening of the material on the sling surface due
to Chemical attack
 Ensure the use of packing to protect the round sling from sharp edges
 Ensure there is no lifting on the point of any hook
 Ensure that the round slings are never exposed to direct heat or flames
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 24 of 22

17.0 LIFTING HAZARD

17.1 HOIST LINE NOT PLUMB.

The working load limits of hoisting equipment apply only to freely suspended loads on
plumb hoist lines. If the hoist line is not plumb during load handling, side loads are created
which can destabilize the equipment and cause structural failure or tip-over, with little
warning.

18.0 EXECUTION

Immediately before any heavy lifting activity, a meeting must be held involving all participants,
including duly assigned representatives of the CONTRACTOR, SUBCONTRACTOR and/or
Package Vendor to fulfil the following functions:

 Review the procedures, requirements, and details specified in the work plans and drawings.
 Review safety items such as weather concerns, plant activity, escape routes, contingency
plans, and locations of fire-fighting and personal safety equipment.
 Designate key personnel such as the signalman, and tagline handlers
 Complete and sign off all appropriate checklists and safety permits.
 Check the placement of all signages and barricades that define the safety boundaries of the
work area.
 Discuss and give due consideration to any additional appropriate steps that any participant
feels is necessary to perform a safe and timely operation.

No one will be allowed to place themselves under a suspended load without an approved safety
device or other means to ensure that the load cannot fall.

All motor vehicles and unauthorized personnel must be kept out of hazardous areas associated
with a heavy rigging activity.
 CLIENT Project Name TSR F44SL Project Phase 1 CONTRACTOR

Document No. F44SL-PHASE1-MIE2-HSE-PRC-0008

Document Title LIFTING PROCEDURE

Revision A Doc. Class Page 25 of 22

Welding to any load while the rigging is attached must be avoided to prevent damage to the load
lines.

No welding or cutting must be allowed on any of the vessels or process equipment.

The CONTRACTOR Project Manager or his designated representative must retain the right to
halt the operation of a sub-/lower-tier contractor any time they see an unsafe act or situation
developing and not allow the operation to continue until the condition is corrected.

For any night work done, artificial light must be provided sufficient to permit the work to be carried
on efficiently and safely.

19.0 APPENDICES

19.1 IPMT PTW PROCEDURE: F44SL-PHASE1-IPMT-HSE-PRC-0001: LIFTING

CERTIFICATE