Technical guidance on the safe use of lifting equipment offshore

This guidance provides technical information for those involved in the supply, operation and control of lifting equipment in the offshore environment. It shows how to apply the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER), and the Provision and Use of Work Equipment Regulations 1998 (PUWER) offshore.

It is aimed primarily at dutyholders, offshore installation managers, managers, supervisors, competent persons and operatives involved in the operation and safe use of lifting equipment offshore. It may also be of use to people working for contractors, equipment suppliers, safety representatives, verification bodies and equipment manufacturers.

It applies to all offshore installations (as defined in the Offshore Installations (Safety Case) Regulations 2005), both fixed and mobile, operating within the UK HSG221 (Second edition) Continental Shelf. Published 2007

HSE Books

© Crown copyright 2007

First published 2002 Second edition 2007

ISBN 978 0 7176 6229 6

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the copyright owner.

Applications for reproduction should be made in writing to: The Office of Public Sector Information, Information Policy Team, Kew, Richmond, Surrey TW9 4DU or e-mail: licensing@opsi.gov.uk

This guidance is issued by the Health and Safety Executive. Following the guidance is not compulsory and you are free to take other action. But if you do follow the guidance you will normally be doing enough to comply with the law. Health and safety inspectors seek to secure compliance with the law and may refer to this guidance as illustrating good practice.

Contents Introduction 4 Who should read this guidance 4 What this guidance covers 4 How you should use this guidance 5 Major regulations and ‘dutyholder’ 5

General considerations 7 Selecting suitable equipment 7 Operation 14

Types of offshore lifting equipment 20 Cranes - variable geometry slewing types 20 Cranes - overhead/gantry travelling types and wire rope hoists 46 Other lifting equipment 49

Equipment for lifting people 55 Introduction 55 Cranes 55 Utility winches and winches used for lifting people 56 Personnel transportation equipment 58 Equipment used in drilling and associated operations for carrying people 62

Drilling eqiupment 65 Introduction 65 Drilling hoisting systems 65 Heave compensated drilling hoisting systems 68 Crown-mounted heave compensators 68 Drill string heave compensators 68 Guideline and riser tensioners 69 Blow-out preventors 69 Pipe handling equipment 69

Appendix 1: Guidance referring to LOLER and PUWER 70

Appendix 2: Glossary 71

References 72

Introduction Who should read this guidance

1 This guidance provides technical information for those involved in the supply, operation and control of lifting equipment in the offshore environment, and shows how to apply the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)1 and the Provision and Use of Work Equipment Regulations 1998 (PUWER)2 offshore. The guidance is primarily aimed at dutyholders, offshore installation managers (OIMs), managers, supervisors, competent persons and operatives involved with the operation and safe use of lifting equipment offshore. Others who may find this guidance useful are:

n people working for contractors; n equipment suppliers; n safety representatives; n verification bodies; and n equipment manufacturers.

What this guidance covers

2 This guidance applies to all offshore installations, both fixed and mobile, operating within the United Kingdom Continental Shelf. Some typical examples are:

n fixed platforms, either manned or of normally unattended status; n mobile installations, eg semi-submersibles, jack-ups, accommodation units and floating production, storage and offloading vessels; n pipe-laying vessels; n crane barges and crane lifting vessels; n well service vessels; n other installations subject to the Health and Safety at Work etc Act 1974 (Application Outside Great Britain) Order 2001 (AOGBO).3

3 It does not apply to seagoing ships and supply boats, for which the Maritime and Coastguard Agency (MCA)4 has jurisdiction. Lifting equipment on these vessels which is part of the ship’s equipment used by the crew (such as that used for loading, unloading, fuelling or provisioning) is not covered by LOLER. Some specific examples of vessels not included in this guidance are:

n standby vessels; n shuttle tankers; n dredgers; and n tugs, anchor handling and survey vessels.

4 It is not possible in this guidance to cover every type of ship or seagoing vessel. You should contact the Health and Safety Executive (HSE) or the Maritime and Coastguard Agency for advice on whether PUWER and LOLER apply to your particular activities.

5 Appropriate sections of this guidance shall be applicable to lifting equipment that is used in conjunction with diving operations and other subsea activities that could be carried out from diving and ROV support vessels. Diving operations and sub-sea activities come under LOLER by virtue of the Health and Safety at Work etc Act 1974 (Application Outside Great Britain) Order 2001. It should be noted that the HSG221 guidance does not cover lifting equipment specifically installed on vessels for the deployment of divers. The term ‘lifting equipment’ as covered in this guidance includes lifting accessories, portable lifting equipment, personnel transfer carriers and lifting equipment used for offshore drilling operations. It does not include:

n fork-lift trucks; n offshore containers and their associated sling sets; n winch units used for the launch/recovery of survival craft such as TEMPSC and other emergency evacuation systems.

6 ‘Lifting operations’ in this guidance does not include manual handling. This is covered by the Manual Handling Operations Regulations 19925 and associated guidance.6

How you should use this guidance

7 The use of lifting equipment, both onshore and offshore, is covered by the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) and the Provision and Use of Work Equipment Regulations 1998 (PUWER) together with their respective Approved Codes of Practice7,8 (ACOPs). These ACOPs set out how you can comply with the Regulations in a general sense, and you will need to refer to them. This guidance will help you find out in detail how to apply these Regulations specifically to offshore lifting equipment and its associated operations.

8 This guidance summarises the most important parts of LOLER (see Appendix 1) and has been arranged around specific topics which will give you practical advice about the management, selection and safe operation of lifting equipment and accessories. Appendix 1 contains a checklist which links the guidance to the main requirements of LOLER and PUWER, and the glossary in Appendix 2 explains the industry terminology that has been used. This guidance does not introduce higher standards or impose any additional requirements to the existing regulations. It aims to clarify what the law requires and illustrates methods for achieving compliance.

Major regulations and ‘dutyholder’

9 The two most important sets of regulations applying to offshore lifting equipment are LOLER and PUWER. They apply onshore to all premises and work situations where the Health and Safety at Work etc Act 1974 (the HSW Act) applies. Offshore they apply to installations, wells, pipelines etc operating within the territorial waters of Great Britain and in designated areas of the UK Continental Shelf in accordance with AOGBO. LOLER specifically deals with lifting equipment and lifting operations. PUWER also applies to the provision and use of lifting equipment and covers other important aspects, such as providing information, instructions, training and maintenance.

10 LOLER and PUWER both place duties on employers, which may bring contractors, consultants, suppliers, verification bodies etc within scope of the Regulations as they all employ people to work offshore. Offshore-specific legislation, such as the Offshore Installations and Pipeline Works (Management and Administration) Regulations 1995 (MAR),9 adopts a different approach, and places duties on the ‘dutyholder’. This term is uniquely applied offshore, and is defined as the operator of a fixed installation and the owner of a mobile installation. If the dutyholder is an employer, who employs people to work on the installation, they will have responsibilities under LOLER and PUWER for their own employees.

11 The dutyholder is required to appoint a manager - the Offshore Installation Manager (OIM) - to command and control the installation and to be responsible for health and safety on a day-to-day basis. This does not alter the dutyholder’s legal responsibility for the health and safety of everyone on the installation. This means that the OIM will need to ensure that all relevant legislation has been complied with - including LOLER and PUWER. MAR requires everyone on the installation to co-operate with the OIM. So, for example, contractors’ employees engaged in crane maintenance will need to make their risk assessments available to the OIM and to others such as employees of other specialist contract firms who may be affected by their work.

12 There are links between LOLER, PUWER and the Management of Health and Safety at Work Regulations 1999 (MHSWR).10 For example, regulation 3 of MHSWR requires a suitable and sufficient risk assessment to be performed for all work activity. This only requires a single risk assessment, which should be carried out by a competent person(s).

13 Throughout this guidance, frequent references are made to the ‘competent person’. In this context, the ‘competent person’ is the most suitable person or persons to agree and implement the recommendations in this guidance. The competent person(s) may be employed by the dutyholder, contractors, verification bodies, a manufacturer, supplier or agent etc. They should have the necessary training, background and experience to be recognised as being competent in the particular field in which they specialise. It is highly unlikely that any one person - or even organisation - will be able to provide all the areas of expertise required throughout this guidance. Instead, a number of people or organisations would be involved.

14 When new legislation is introduced, unless specified in the associated statutory instrument, there is normally no requirement for new provisions to apply retrospectively. However, there are general requirements for employers to ensure, so far as is reasonably practicable, the health and safety of all employees at work. This duty covers the equipment provided, its maintenance and the systems of work that are used. In discharging these responsibilities, the employer has to take account of new technology and innovations, and the greater reliability or effectiveness that may be provided by new equipment. The greater the risks (for example, risks that occur during man-riding or lifting over live processing plants or well heads) then it is more likely that it is reasonable to go to very substantial expense, trouble and invention to reduce these risks. It is important that employers and their appointed competent persons are continually checking to ensure that old and existing lifting equipment is suitable and fit for purpose and does not pose any increased risk during operations. This is the requirement under the HSW Act.

15 While employees do not have duties under LOLER, they do have general duties under the HSW Act and MHSWR to take reasonable care of themselves and others who may be affected by their actions and to co-operate with others.

General considerations Selecting suitable equipment

16 You should select lifting equipment which is suitable for the operations it will be required to perform. You should base your final selection on a risk assessment of the proposed use of the equipment. Before starting to use them, the dutyholder and the competent person should satisfy themselves that lifting appliances and any associated equipment have been designed, manufactured and verified fit for purpose in accordance with recognised codes and standards applicable to the offshore industry.

Risk assessment 17 The risk assessment should include, as a minimum:

n an analysis of failure modes and their consequential effects; n personnel protection requirements; n effects of abnormal situations, eg gross overloading; n emergency procedures for recovering loads or personnel; and n human factors.

18 If a lifting system is to be adapted for a new operation (different from the one it was first installed for), or if it is to be moved to a new location, then it will need a full risk assessment covering its intended new use. This should be approved by a competent person.

19 There are particular factors in the offshore environment which you should consider when assessing both the technical and operational aspects of lifting and handling tasks. You should incorporate these into the risk assessment, together with any special factors such as use of the equipment in explosive atmospheres.

Details of service 20 You may need to discuss the suitability of lifting equipment with the supplier. You will also need to provide details of service. You will need to consider the factors below when deciding the correct equipment for a particular task:

n maximum sea state; n maximum wind velocity; n maximum and minimum ambient temperatures; n snow/ice build-up; n immersion in sea water; n supply vessel excursion; n movements of the installation/vessel, ie heel, trim and pitch; and n exposure to chemicals and other hazardous substances.

21 You will also need to consider how often the lifting equipment will be used and advise the supplier of any regular periods of inactivity or extended periods of non- use. If you need a mobile crane, you should also tell the supplier whether it will need to operate free on tracks or wheels, fixed or tied down or travelling with the load.

Specifications 22 The competent person (see paragraph 13) should ensure, as far as is practicable, that the equipment supplied:

n has been manufactured from suitable materials and constructed to approved quality standards; n has adequate safety factors; n has adequate levels of performance; and n where appropriate has responsive controls and safety systems.

23 For slewing cranes which perform sea-state lifting, a competent person selected by the dutyholder should ensure that the crane has adequate hoist speed and power to perform correctly in all modes of operation. Low hoist speeds may restrict the number of falls of rope that can be used for a particular sea state and so limit the lifting capacity of the crane. It is essential to prevent risks and hazards arising from the under-performance of cranes. The competent person should ensure that the following aspects of crane performance are considered:

n The hook speed should be fast enough for the specified sea states to prevent the load re-impacting with the supply vessel. The height of adjacent containers on the deck of the supply vessel should be taken into account. n The speed of slew, boom and hoist motion should be fast enough for the operator to keep the hook/load line sensibly plumb within the excursion envelope of the supply vessel and within the specified offlead and sidelead parameters. n Using two or more crane services should not cause undesirable motions of the hook/load. n The prime mover should be prevented from stalling or over-heating under maximum power demand, whatever the configuration of the crane. n Uncontrolled overhauling and/or free fall of the load hoist and boom hoist system and uncontrolled slewing motion of the crane are dangerous and should be prevented.

24 However, some cranes may incorporate emergency release devices to prevent gross overloads (for example arising from a snagged hook/load), and when these are actuated they may automatically override some of the features listed above. All emergency release devices should be made inactive every time the load travels across areas of the installation.

25 For slewing cranes (pedestal or mobile), lifting duty charts - including environmental and/or operational limitations - should be clearly and permanently displayed at the operator’s control station and be included in the operational manual. For cranes that undertake sea-state lifting, the duty charts should have reduced lifting capacities appropriate to dynamic factors for the prevailing sea state. These should be agreed by a competent person. A suitable rated capacity indicator (RCI) should be fitted that covers all duty ratings the crane will be subjected to, for both inboard and sea-state lifting operations. It should be possible, either manually or automatically, to change the load rating of the crane in accordance with the sea- state/inboard lifting duty charts.

26 As appropriate to the type of lifting equipment (and as required), you should provide lifting duty/rating charts according to the service parameters. These charts should be drawn up using recognised de-rating methods and procedures, such as laid down in codes of practice issued by the various verification bodies. Dynamic factors should be based on information obtained from standards and codes used for the design and component selection for the crane.

27 You should ensure that for beam cranes, gantry cranes, trolley hoists or any equipment that can lift and/or travel the load, the travelling system remains captive to its rails and/or its points of attachment. The load should remain captive to its hook or attachment point under all conditions of service.

28 When using rope/chain hoists, the evaluation of loading in the supporting structure, such as runway beams, trolleys, pad eyes etc, should include:

n the load on the hook; n the weight of slings and attachments; n the weight of the hoist unit/trolley; and n as appropriate, the pulling force on the hand chain.

For routine lifts this only needs to be carried out on an initial basis and re-evaluated only for non-routine operations.

29 Loose accessories for lifting, such as strops, slings, pennants and spreader beams, should be supplied with suitable documentation stating that they have been tested, inspected and verified as being fit for purpose. See also paragraphs 52-55.

Material selection 30 Materials used in the primary load path (including foundations and both permanent and temporary attachment points) should be chosen according to recognised standards and to the specific requirements and limitations agreed with the competent person.

31 Material certificates for all primary elements, including castings and forgings, should provide details of all necessary chemical and mechanical properties, including fracture toughness values at specified low temperature conditions where appropriate. Mechanical properties of materials should be quoted after any heat treatment which may have altered the original properties. It is perfectly acceptable to use test coupons to obtain these properties, provided they have been subjected to the