LIFT PLAN

PROCEDURE

KCAD GLOBAL EMERALD

RIG MAST TANDEM LIFT

(COMPLEX LIFT)

Date Prepared by Reviewed by Approved

10 February 2011
KCAD GLOBAL
LORENZO DESEO
EMERALD

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CONTENTS PAGE NO.

1. PURPOSE………………………………………………………………….3

2. SCOPE………………………………………………………………….…..3

3. REFERENCE DOCUMENT……………………………………………....3

4. LIFT CATEGORY ……………………………………...………………….3

5. RESPONSIBILITIES..............................................................…..........4

6. LIST OF PERSONNEL........................................................................4

7. LIFTING TACKLES & ACCESSORIES...............................................5

8. LIFTING EQUIPMENT DESCRIPTION...............................................6

9. LOADING…….....................................................................................7

10. CRANE PRECAUTIONS...................................................................7-8

11. HAZARD IDENTIFICATION….............................................................9

12. ACCESS & EGRESS TO THE SITE….............................................9-10

13. SITE PREPARATION ……………………………………………...…11-12

14. CRANE POSITIONING ………………………………….……………13-14

15. RIG MAST LIFTING SEQUENCE…...............................................15-18

16. CONTINGENCY…………..…………………………………………….…19

17. LIFTING DOCUMENT ATTACHMENT ………………………..……19-44

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1.0 PURPOSE

This lifting plan covers the lifting activity of GLOBAL EMERALD RIG MAST at
MCY, Kuala Belait, Brunei Darussalam. The purpose of this lifting plan is to
provide guidance for responsible crane lifting practices and identify lifting
hazards beforehand. This lifting plan contains the minimum standards to be
followed and will apply to all personnel working for the project.

2.0 SCOPE

This lift plan covers lifting of Rig Mast by 250te & 160te crane tandem lift from
the top of choker beams at MCY quayside to Kim Heng Barge.

3.0 REFERENCE DOCUMENT

- BS 7121
- LOLER Regulation
- BSP-ASS Standard-004 Revision 1; BSP-Lifting and Hoisting Standard

4.0 LIFT CATEGORY

This lift satisfies the conditions of a COMPLEX LIFT.

1. Two pieces of lifting equipment are required to work unison i.e. tandem
lifts.

2. The gross load is greater than 75 tonnes.

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5.0 RESPONSIBILITIES
Person in Charge
• He shall be the overall in charge and ensure safe lifting operations.
Worksite Supervisor
• He shall apply appropriate work permit for the lifting operations.
• He shall be responsible to make sure that procedures for lifting and
hoisting are being implemented.
Banksman
• Is the competent person to provide appropriate signal to the crane
operator on the direction of the load to location as what been planned
& agreed. He must position himself in full view of the crane operator.
• He should be wearing reflective vest for easy identification.
Crane Operator
• To ensure the crane and lifting equipments to be used are in good
working conditions & compliant like valid third party inspection
certification.
• To take instruction from the assigned Banksman wearing the vest.
• To comply with the procedures for operating crane.
• To carry out the lift according to the Lifting Plan.
Riggers
• Shall be responsible for preparing and slinging a load in readiness for
the lifting operations.
• He is also responsible for attaching or detaching slings to and from
hook block.
• He shall ensure that rigging slinging safe practices had applied on
every lift.

6.0 LIST OF PERSONNEL

NO. NAME RESPONSIBILITY REQUIRED PPE

Hard Hat, Coverall, Safety
1 Juver Cacayan Banksman Glass, Safety Boots, Hand
Gloves & Reflective vest
Hard Hat, Coverall, Safety
Crane Operator
2 Pheera Pannak Glass, Safety Boots, &
(250 te Crawler)
Hand Gloves
Hard Hat, Coverall, Safety
Crane Operator
3 Kong Thau Fui Glass, Safety Boots, &
(160 te Crawler)
Hand Gloves
Hard Hat, Coverall, Safety
3 Jeffri Bakar Rigger Glass, Safety Boots, &
Hand Gloves

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Hard Hat, Coverall, Safety
4 Rakum Rigger Glass, Safety Boots, &
Hand Gloves
Hard Hat, Coverall, Safety
5 Jomon Jangalay Rigger Glass, Safety Boots, &
Hand Gloves
Hard Hat, Coverall, Safety
6 Mohd Malek Shaiful Rigger Glass, Safety Boots, &
Hand Gloves

7.0 LIFTING TACKLES / ACCESSORIES

7.1) 250te crane (Main boom)

Lifting Tackles Qty Capacity (Kg) Size Weight (Kg)

Included in
Slings, Spreader 1 SWL 50,000 /
1.0 - Mast gross
Beam & Shackles set piece
wt.
Crane’s Hook
2.0 1 SWL 150,000 - 2,300
(250te Crane)
Total 2,300 = 2.3te

160te crane (with fixed 18.3m fly jib)

Lifting Tackles Qty Capacity Size Weight (Kg)

(Kg)
Included in
Slings, Spreader SWL 50,000 /
1.0 1set - Mast gross
Beam & Shackles piece
wt.
Crane’s Hook
2.0 1set SWL 160,000 - 2,800
(160te Crane)
Total 2,800 = 2.8te

Note 1: GEM dedicated slings, spreader beam and shackles are fitted to the
Mast shall be used for the tandem lift by using two cranes at each side.

Note 2: The load rating shown in the load chart includes the value of the main
boom and/or with fixed jib except for the main hook block, sling and other load
handling accessory. Refer to attachment 1, pages 23 & 28 for details.

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7.2) LOAD WEIGHT DISTRIBUTION

43.2 te 32.0 te

7.2.1 Rig Mast including spreader beam & shackles is 75,200 Kg. Rig mast is slightly
heavier on one side from previous tandem lift as shown above. This difference or
shift of COG will be compensated during the tandem lift.

8.0 LIFTING EQUIPMENT DESCRIPTION

*Track
Boom Pads Track
Rated Outriggers
Description Length Imposed Pad
(te) (Full)
(Max) Pressure size/each
2
(Kg/ m )
1 250 Tonnes Hydraulic
Crawler Crane with
counterweight without fly
45.7 m 1.07m x
jib. SWL 71.2 N/A. 10,382
(6 part-line) 8.97m
Serial No. JD04-02362
Model: 7250-2 Crawler
Crane
2 160 Tonnes Hydraulic
Crawler Crane with
counterweight with fitted
18.3m fly jib. 42.7 1.07mx
SWL 74.3 N/A 7,958
Serial No. JC04-02156 (6 part-line) 8.36m
Model: JC04-
02156/CKE 1600
Crawler Crane
* Crane Total Loading + Gross Load: 217te + 45.6te = 263te (250te crane), 145te+45.6=191te (160te crane)

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9.0 LOADING

9.1 Rig Mast

Gross Dimension (mm) Type of

No. Item Weight
L W H Rigging
(Kg)
Rig Mast (incl.
1 75,200 25000 5500 6000 Pad eye
lifting tackles)

9.2 GROSS WEIGHT DISTRIBUTION (TANDEM LIFT)

• 250te CRANE
ITEM WEIGHT (Kg)
Rig Mast & Traveling Block including 43,200
Slings, Spreader Beam & Shackles
Contingency (10%) 4,320
Lifting Tackles/Accessories 2,300
Gross Weight 49,820

• 160te CRANE
ITEM WEIGHT (Kg)
Rig Mast & Traveling Block including 32,000
Slings, Spreader Beam & Shackles
Contingency (10%) 3,200
Lifting Tackles/Accessories 2,800
Gross Weight 38,000

10. 0 CRANE PRECAUTIONS

1. Prior to crane positioning, ground condition must be surveyed. Underground

services shall be protected by Steelcon or equivalent means of protection
against damage.

2. Crane access must be checked for obstruction such as pipes, lamp posts,
structures, etc. Proper crane access shall be provided and obstruction shall be
cleared or protected against damage.

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3. Crane position shall be identified and crane’s track pad must be properly
supported.

4. Electric power line hazards must be surveyed. Follow the safe distance when
working near power line.

5. Identify lift near roads; temporary road closure shall be done.

6. Personnel involved shall be limited during lifting, (PIC, Operator, Banksman

and Riggers), control unauthorized entry by barricading the affected area and
provide “Lifting In Progress” signage.

7. HIP for crane lifting shall be in place and must be briefed to all workers
involved during toolbox meeting.

8. All lifting tackles and equipment shall be inspected before use. Ensure that
certificates are available for verification.

9. Daily functional test must be carried by crane operator, third party inspector or
surveyor shall be called on to decide on the action needed.

10. Outriggers shall be fully extended every crane position.

11. Provide enough tag lines (minimum 2) when required to keep Riggers away
from the load.

12. Two way radios shall be used by the Banksman and Crane operator as a
means of communication. The Banksman shall stand in a position where he
has the clear view of the lifting and see any potential crane boom collision
points.

13. Weather condition must be observed at any time, PIC shall ensure that wind
speed is satisfactory (Wind force of 4 – moderate breeze – 5-8 m/sec),
maximum 1.5m sea swell & 3 degrees Barge pitch & roll for safe lifting
operation. Lifting shall be suspended when raining.

14. Riggers shall maintain safe distance (1 meter rule) from the load during the lift.
For every 1 meter height position shall be 1 meter away from the load with the
use of tagline when required.

15. Warn other personnel in the area of the movement of the load. Do not move
the load over personnel.

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11.0 HAZARD IDENTIFICATION

11.1- PROXIMITY & LOAD

PRESENT? REMARKS
PROXIMITY
YES NO
Overhead Power Lines √
Other Overhead
√
Obstacles
Underground services √
Excavations √
Unstable/Soft Ground √
Hazardous
√
Chemicals/Materials
Confined Working Area √
Restricted Access – width √
Other Hazards Identified. √
LOAD
Lifting Point Certification √
Slinging Difficulties √
Top Heavy √
Sharp Edges √
Other Hazards Identified √

11.2 – HAZARD IDENTIFICATION PLAN

Please refer to attachment no.5

2.0 ACCESS AND EGRESS TO THE SITE

Note: 250te Crawler Crane will be transported divided into different parts using
trailers and to be assembled onsite. 160te crane does not require to be transported
since it is readily available onsite.

Counterweight
Transport Weight
Crane (Upper+Lower)
(Kg)
(Kg)
KOBELCO 7250-2 44,500 117,100

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MCY ENTRANCE / SECURITY

SITE OF LIFTING & CRANE

ASSEMBLING AREA

B ROUTE OF EQUIPMENTS
A ENTERING & LEAVING THE
R YARD
G
E

KIM HENG BARGE & RIG

MAST LOCATION

NOT TO SCALE

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13.0 SITE PREPARATION

The barge must be positioned closer to the quayside to provide and lessen the
working radius & increase capacity of the cranes during the lift. See below diagram.

The site ground preparation shall be done by the lifting contractor (Megalift). Laying
of 12 pcs of steel plates (6.0m x 1.2m x 1.0in) on the crawler cranes’ path as shown
below.

DEFENDER
1.0

18.0

CHOKER BEAM
UNDERNEATH

9.2

KIM HENG STEEL PLATES

BARGE

UNIT: METER

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14.0 CRANE POSITIONING

14.1 Crane Position

DEFENDER
1.0

15.0

.0 160te
10
R= Crawler
Crane

4.4

R=14.0
250te
Crawler
KIM HENG Crane
BARGE
QUAYSIDE

UNIT: METER

Fig.1
TOP ELEVATION

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SIDE ELEVATION
Fig.2

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15.0 RIG MAST LIFTING SEQUENCE

Two cranes must perform simulation of the tandem lift following the figure
below before commencing any lift. This is to verify correct position, actual
working radii and capacity of the crane as defined in the lift sequence.
Reading from crane’s load indicator (ASLI) with regards to crane capacity,
boom length & working radius can be cross-referenced with the load chart to
check for any difference. Crane operators & banksman will communicate
using two way radios on agreed clear channel.

• POSITION A
Both 250te & 160te crane will lift up the Mast. The two cranes will do test
lift holding the load 0.3 m high from the choker beams for at least 3
minutes. At this time, the banksman should check any anomaly on the
lifting tackles and crane stability.

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DEFENDER
1.0

.0 160te
10
R= Crawler
Crane

R=14.0

250te
Crawler
KIM HENG Crane
BARGE

UNIT: METER

POSITION A
250te CRANE 160te Crane
Boom Length 45.7 m Boom Length 42.7 m
Operating Radius 14.0 m Operating Radius 10.0 m
Lifting Angle 720 Lifting Angle 760
Elevation Height 43.5m Elevation Height 41.5m
Capacity 71,200Kg Capacity 65,900Kg
Loading 49,820 Kg Loading 38,000 Kg
Load Factor 70% Load Factor 58%

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• POSITION B

The two cranes will slew the mast as shown below. Then, the two cranes
will start reversing simultaneously, at the same slewing to provide enough
space. At this stage, the banksman must communicate continuously with
the operators using the two way radios during the maneuver.

B
QUAYSIDE

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POSITION B
250te CRANE 160te Crane
Boom Length 45.7 m Boom Length 42.7 m
Operating Radius 14.0 m Operating Radius 9.0 m
Lifting Angle 720 Lifting Angle 780
Elevation Height 43.5m Elevation Height 41.7m
Capacity 71,200Kg Capacity 73,800Kg
Loading 49,820 Kg Loading 38,000 Kg
Load Factor 70% Load Factor 51%

• POSITION C

At this position, the 250te crane will move forward while slewing to lessen the
radius and increase its capacity.

160te
Crawler
Crane
R=9.0

250te
2.0 Crawler
R=1 Crane

FORWARD

KIM HENG
BARGE

UNIT: METER

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POSITION C
250te CRANE 160te Crane
Boom Length 45.7 m Boom Length 42.7 m
Operating Radius 12.0 m Operating Radius 9.0 m
Lifting Angle 750 Lifting Angle 780
Elevation Height 44.1m Elevation Height 41.7m
Capacity 85,100 Kg Capacity 73,800Kg
Loading 49,820 Kg Loading 38,000 Kg
Load Factor 59% Load Factor 51%

• POSITION D
250te & 160te cranes will move forward while slewing to lessen the
radius and increase its capacity. 250te crane will hoist down one side of
mast to position for the pins while the 160te holding the other end. 160te
crane will only hoist down the mast once the pins is done

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POSITION D
250te CRANE 160te Crane
Boom Length 45.7 m Boom Length 42.7 m
Operating Radius 12.0 m Operating Radius 12.0 m
Lifting Angle 750 Lifting Angle 740
Elevation Height 44.1m Elevation Height 41.0m
Capacity 85,100 Kg Capacity 54,000Kg
Loading 49,820 Kg Loading 38,000 Kg
Load Factor 59% Load Factor 70%

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Note: Load factor denotes Crane capacity, dynamic or static lift. Approximately
100% load factor will trigger Crane’s Rated Load Limiter or cut off function of the
crane.

16.0 CONTINGENCY
In the event of emergency/incident during the operation, the personnel
involved in the operation must follow the KCAD/MCY emergency response at
all times. Coordination with the site representative is a must.

17.0 LIFTING DOCUMENT ATTACHMENT

Attachments1 – CRANE CERTIFICATION AND LOAD CHART

Attachment 2 – LIFTING TACKLES CERTIFICATION

Attachment 3 – PERSONNEL CERTIFICATION

Attachment 4 – CRANE BANKSMAN HAND SIGNAL

Attachment 5 – HIP AND TOOLBOX TALK FORM

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ATTACHMENT 1

CRANE CERTIFICATION AND LOAD CHART

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250te Crane

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250te Crane Load Chart

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250te Crane

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250te Crane

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160te Crane Certificate

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160te Crane Load Chart

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160te Crane

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160te Crane

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ATTACHMENT 2

LIFTING TACKLE CERTIFICATION

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Mast, Slings, Spreader Beam and Shackles Certificates

(C/O KCAD/Global Emerald)

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ATTACHMENT 3

PERSONNEL CERTIFICATION

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ATTACHMENT 4

CRANE BANKSMAN HAND SIGNAL

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ATTACHMENT 5

HIP AND TOOLBOX TALK FORM

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