BP Pakistan

Exploration & Production, Inc.

LIFTING OPERATIONS: GUIDELINES FOR SAFE OPERATION OF

PIPE LAYERS (SIDE BOOMS)

Document Linked to: PRO/SFTY/017

 BP Pakistan Exploration & Production, Inc.
GUIDELINES FOR SAFE OPERATION OF PIPE LAYERS Rev. No. 1

Table of contents

Section Title Page

1. INTRODUCTION………………………………………….… 3

2. PURPOSE & SCOPE……………………………………

3

3. LINKAGE WITH OTHER PROCEDURE & STANDARDS 3

4. DEFINITIONS. ……………………………………… 4

5. RESPONSIBILITIES.……………………………………… 6

6. COMPONENTS OF SAFE OPERATION………………… 6

7. PREVENTIVE MAINTENANCE, INSPECTION & CERTIFICATION.

…………………………………………… 7

8. SAFE SYSTEMS OF WORK. ………………………………… 7

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GUIDELINES FOR SAFE OPERATION OF PIPE LAYERS

1.0 INTRODUCTION

Pipe layers (side booms) are employed for the construction of cross country pipelines, for
their ability to lift and lower string of pipeline in unison in all kinds of terrains ranging
from mountainous ridges to rough plains, deserts and waterlogged areas. The power and
ability of pipe layers while making them indispensable in the construction of pipelines,
also offer hazards in their operation. Human error is a contributing factor in most
equipment related injuries; haste, carelessness and lack of training are the primary causes
of injuries. Most operating injuries occur because of excessive speed, loss of control,
failure to observe warning signs, slipping or falling while entering or dismounting, a lack
of seat belt or not watching in the direction of travel or boom. A careful operator is the
best insurance against an accident.

The pipe layer (side boom) operators must be trained to work safely with the machine
and have good knowledge of pipe line construction activities, and comprehend associated
simultaneous operations. Additionally, all pipe layer operations and maintenance shall be
in compliance with all applicable regulations and standards.

2.0 PURPOSE AND SCOPE

The purpose of these guidelines is to ensure safe working equipment, conditions and
practices during pipe layer operations on and off the field. These guidelines apply to
contractors or sub- contractors engaged in the construction of pipelines for on or behalf of
BPP within Company work sites or out side in Badin concession.

This document is to ensure that all pipeline construction activities involving pipelayer
operations, across BP Pakistan’s Badin concession, are in compliance with applicable
regulatory requirements, international standards and regulations and Company
requirements, whichever the highest.

The key requirements and components of this document are:

 Pipe layer operators’ selection, training and authorization requirements.

 Safe Operations of Pipe layers.

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GUIDELINES FOR SAFE OPERATION OF PIPE LAYERS

3.0 LINKAGE WITH OTHER PROCEDURES AND STANDARDS

These guidelines have linkages with the following procedures, rules, standards and
regulations. These must be consulted prior to any lifting operations.

a) BPP Permit to Work Procedure (PRO/SFTY/005)

b) BPP Task Risk Assessment Procedure (PRO/ SFTY/ 018).

c) BPP Incident Reporting Procedure

d) Guidelines for Lifting Equipment Inspection.

4.0 DEFINITIONS

The following definitions shall assist in the understanding of this procedure:

Rated Capacity Rated capacity is the maximum weight the pipe layer can
lift, lower or transport in stable condition with the full
opening of counter weights.

Authorized Operator An experienced and qualified person who has undergone

training and subsequent certification by a Company-
approved Third- Party Training Authority and is designated
to operate pipe layer/ side boom.h

Company Representative A person who, by virtue of appointment, has authority to

represent BP Pakistan in all matters with the Contractor
concerning performance poof work, provision of services,
or supply of goods.

Equipment Checklist List identifying attributes required to be checked and

approved, prior to equipment entry into Company work
sites.

Facility Any location including Construction, Drilling,

Maintenance, Productions, Warehouse, and Camps within
Company area of operations where work is being carried
out for and on behalf of the Company.

Facility-in-charge/ Company’s senior-most supervisor who is present at the

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Location Supervisor location and is responsible for carrying out operations

within the facility area.

Safe Working Load (SWL) The relevant safe working load required to be specified in
records of test and examinations, and to be marked on the
lifting equipment and the lifting gear.

Task Risk Assessment Tool used for listing distinct activities within a job
(TRA) identifying various associated risks, categorizing these risks
on severity, and chalking-up a safety plan to remove/
control such risks.

Third- Party Inspection & An internationally recognized/accredited lifting equipment

Certification Authority inspection and certification agency approved by BP
Pakistan.

Third- Party Training An internationally recognized training agency approved by

Authority. BP Pakistan.

Work Permit A document issued by a Permit Issuing Authority allowing

the performance of a specific tasks in a specified location
for a specific duration, identifying associated hazards and
control measures required.

Maintenance Work, such as fluid replacement and lubrication, that the

manufacturer specifically states in their owners manual as
“maintenance”, and that can generally be accomplished
without the use of special tools or need for specialized
knowledge.

Repair Work Work that generally requires special tools and knowledge
about the equipment being worked on. This includes
structural modifications, and equipment installation.

Frequent Inspection Inspection of lifting appliances and accessories carried out

according to this procedure or national/ international
standards at frequencies varying from daily to monthly
intervals.

Periodic Inspection Inspection of lifting appliances and accessories carried out

according to this procedure or national/ international
standards at frequencies varying from 1- month to 12-
month intervals.

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5.0 RESPONSIBILITIES

Following personnel are responsible for ensuring compliance with this procedure, and
with applicable regulatory requirements relating to mechanical handling of line pipes
involving pipe layers operation:

5.1 Location Supervisors

Location Supervisors shall include Production Team Leaders, Senior Production

Operators, Lead Operators, Construction Team Leaders, Construction Superintendent,
Warehouse Supervisor, and Rig Move Coordinator etc. They shall ensure that:

5.1.1 All Pipe-layers and associated lifting attachments, appliances and accessories are
certified from a BP approved third party inspection and certification authority.
5.1.2 All Pipe-layers and associated lifting attachments, lifting appliances and
accessories are inspected before use.
5.1.3 Pipe-layer (Side-boom) Operator is trained, competent and certified for its
operation.
5.1.4 The pipeline string is safe and properly attached/ hooked up, and within the
capacity of the Pipe-layer.

5.2 Pipe-Layer (Side-Boom) Operator

Pipe-layer Operators must be trained, competent and certified for its operation. He is
responsible for ensuring safe & good condition of his equipment/ machine and for its
operation within its safe limits. He shall:

5.2.1 Check the condition of Pipe-layer (Side-boom) and all its attachments and
accessories before starting work.
5.2.2 Report to his supervisor any obvious defects or required repairs.
5.2.3 Maintain safe clearances from energized overhead electric power cables.
5.2.4 Always look in the intended direction of travel or direction of boom and hook, to
be sure personnel or allied equipment does not interfere with the machine work
pattern.
5.2.5 Report any unplanned incident that may have adversely the machine (side-boom)
and associated equipment.

6 COMPONENTS OF SAFE PIPE-LAYER OPERATIONS

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Following activities shall be ensured to achieve safe operations associated with Pipe-
layers.

6.1 Every one has the right to stop the work when its unsafe.
6.2 It will be ensured that Pipe-layers and associated equipment are fit for use and
their certification by a BP Pakistan approved third- Party Inspection Authority is
valid.
6.3 BPP authorized person will conduct a pre-use inspection on approved checklist
format.
6.4 Any noted deficiencies and/ or defective parts noted during the inspection should
be repaired or replaced prior to continuing to use the Pipe-layer. BPP
representative will ensure that in case of deficiencies noted during inspection,
these are properly addressed/ repaired prior to taking the Pipe-layer in service.
Third Party surveyor will inspect the Pipe-layer after repairs and issue fitness
certificate.
6.5 Rated load capacities or other hazard warnings will be conspicuously posted on
the Pipe-layer.
6.6 Pipe-layer load limits are adhered to at all times. The operator must have clear
idea of the lifting capacities of his machine vis-à-vis load subjected on it during
lifting and lowering operation of pipeline string.
6.7 A Preventive Maintenance (PM) program is required for all the Pipe-layers.

7.0 PREVENTIVE MAINTENANCE, INSPECTION, AND CERTIFICATION

A Preventive Maintenance (PM) Program shall be applied by the contractors for the pipe-
layers owned or hired by them, in accordance with the manufacturer’s specifications and
shall be properly recorded for reference and tracking. Maintenance program shall include
not only mechanical components, but also all alarm/ safety devises and lifting
attachments and accessories. In addition to the regular maintenance, all Pipe-layers shall
be inspected and certified every year by a Company’s approved Thirds Party Inspection
Authority. The surveyor/ examiner shall issue certificates to equipment passing
inspection.

8.0 SAFE SYESTEMS OF WORK FOR OPERATION OF PIPE-LAYERS

Human error is a contributing factor in most equipment related injuries; haste,

carelessness and lack of training are the primary causes of injuries. Most operating
injuries occur because of excessive speed, loss of control, failure to observe warning
signs, slipping or falling while entering or dismounting, a lack of seat belt or not
watching in the direction of travel or boom. A careful operator is the best insurance
against an accident.

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GUIDELINES FOR SAFE OPERATION OF PIPE LAYERS

8.1 Always wear proper safety equipment (PPE). Avoid wearing jewelry and
loose fitting clothing. All operators shall be provided with the following as
a minimum requirement.

8.1.1 Hard Hat

8.1.2 Protective Footwear.
8.1.3 Gloves appropriate for task.
8.1.4 Coveralls
8.1.5 Ear/ Eye Protection, if appropriate.

8.2 Only competent, qualified and certified Operators will be authorized to

operate the Pipe-layer.

8.2.1 The operator must be alert, physically fit and free from the
influences of alcohols, drugs or medications that might affect his
eyesight, hearing, reactions or judgment.
8.2.2 Operator Authorization/ Certification must be renewable after a
specific period, and is liable to be withdrawn if the Operator fails
to comply with safe working Procedures.
8.2.3 The Operator shall be strictly accountable for ignition keys and
keys shall not be left in the Pipe-layer unattended.
8.2.4 The Operator must carefully evaluate particular application and
machine, and safety equipment such as warning lights, side view
and rear view mirrors, backup alarms, fire extinguishers, rotating
beacons etc.
8.2.5 The Operator must perform a visual check of the machine before
starting the engine. Look for things such as improper fluid levels,
oil leaks, and loose, damaged or missing parts. He will ensure not
to start the engine until any unsafe conditions are corrected. Secure
all caps and filler plugs.
8.2.6 The operator must know and understand the traffic flow patterns of
the job and should always obey flagman, signs and signals. He
must check work area for hazardous conditions, and be alert for
soft ground conditions, near drop offs or excavations or fill
material, which could lead to sudden tipping of the machine.
8.2.7 Safety must always be the operators most important concern. He
must refuse to operate when he knows it is unsafe and consult his
supervisor when safety is in doubt.

8.3 The machine should not be serviced with anyone in the operator’s
compartment unless said person is qualified to operate the machine and is

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assisting in the servicing. Unauthorized personnel should not be allowed

to operate, maintain or service the machine.

8.4 Before entering the operator’s compartment, clear the immediate

surrounding the machine of personnel and obstructions. Walk completely
around the machine.

8.5 Be sure the area of the operator’s compartment, all mounting steps and
grab handles are free of oil, grease, loose objects, ice and mud to prevent
the possibility of slipping. Remove or secure all maintenance and personal
items so they will not interfere with the operator or jam the controls.

8.6 Do not use controls or hoses as hand holds when climbing on or off the
machine. Hoses and controls can move and do not provide solid support.
Movement of the controls may cause inadvertent and unexpected
movement of the machine or its equipment.

8.7 Always sit in the operator’s seat before operating any controls. Keep
operating controls, hands and shoes free of grease, water and mud to
insure positive control functions.

8.8 Never check battery charge by placing a metal object across the battery
posts. The sparks could cause can explosion. Always use voltmeter for
checking battery state of charge.

8.9 Always place the transmission selector in neutral and apply the neutral
safety lock and lock the parking brake before starting.

8.10 Perform an operational check of the machine in a safe area before putting
it to work. Check all controls, including the brake pedal, steering pedals,
transmission selector, crane auxiliary equipment: check up the condition
of the connections of the jib, winch, pulley blocks, roping and controls of
the working equipment. Check up the guiding of the working ropes, any
possible defects of the ropes and whether they are correctly wound on the
drums. Check all gauges, warning lights and safety devices. Correct any
malfunction.

8.11 Do not exceed the values of permissible load specified in the maximum
lifting capacities.

8.12 Only one person, the operator, should be permitted to ride on the machine
when it is in operation. Never haul passengers.

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8.13 At night and times of poor visibility, carefully check the area before
moving in with the machine. Use all lights when so required.

8.14 Keep the machine at safe distance from excavations so as not to cause
slide of the ground.

8.15 Do not use defective lifting slings or lifting slings of insufficient strength.

8.16 Check-up periodically the condition of the roping of the pipe-laying

machine. Check the roping for damages or wear and proper fastening.
Check up whether the ropes are guided correctly.

8.17 The evaluation of the rope wear is carried out on the basis of the number
of broken wires or the rope, amount of rust, wear of the wire sand other
defects like: loosening of the wires and strands, deformations etc.

8.18 During operation of the machine, especially when the hook and boom are
lowered, always ensure that there are at least three full rope coils left on
the winch.

8.19 When moving the machine, with its own drive, over well-timbered region,
built area or difficult area, the presence of look out should be ensured to
guide or to assist the operator to move through those difficult areas. The
machine should not be allowed to move while obstacles are lying on the
road.

8.20 During the brake lock test, be sure that there are no people in the
surroundings of the machine, and that the same is free from obstacles. In
case the brakes fails to break the machine or the winch drums, stop the
machine operation immediately and rectify the cause of defect.

8.21 When operating the machine, look in the intended direction of travel or
direction of boom and hook, to be sure personnel or allied equipment does
not interfere with the machine work pattern.

8.22 Avoid crossing obstacles such as ridges, rocks or logs. In case of

unavoidable, reduce speed and ease over the obstacle at an angle.

8.23 Machine’s weight and the vibration can collapse the walls of excavation.
Keep the machine back from the edges of banks and excavations.

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8.24 Never mix gasoline, gasohol and/ or alcohol with diesel fuel. This practice
creates an extreme fire hazard and under certain conditions an explosion,
which could result in personal injury or an accident.

8.25 Never remove the fuel tank filler caps or refill the fuel tanks while the
engine is running or when the machine is indoors. Fumes are dangerous, a
spark or flame could result in a fire or explosion.

8.26 Always operate at slow speeds to insure complete control of the machine.
Travel slowly in congested areas or on roughs ground or near drop offs,
slopes or slippery areas.

8.27 Do not operate the machine in a condition of extreme fatigue or illness.

8.28 Keep your work area as smooth as possible and free of obstruction.

8.29 Always check condition of seat belt and mounting hardware before
operating machine. Replace any damage for worn parts. Seat belt and
mounting hardware must be inspected for wear or damage. Replace the
belts or mounting hardware if worn or damage.

8.30 When pulling or towing with a chain or cable, take up to the slack
carefully. A sudden jerk could snap the chain or cable causing it to whip
dangerously. Do not pull or tow unless the operator compartment is
guarded for a whipping chain or cable. Clear personnel from the area. Be
sure chains or cables and their anchor points are strong enough to handle
the expected load. Inspect carefully for flaws before using. Always wear
gloves when handling chains or cables. Avoid kinking the chain or cable.
Do not pull with a kinked chain or cable as the high stress could cause a
failure in the kinked area. Use only designated towing or pulling
attachments points. Be sure pins are attached securely before pulling.

8.31 Do not adjust the seat position while the machine is in motion. A loss of
control may result. Always stop the machine and apply brakes before
adjusting the seat.

8.32 Never leave the machine un-attended while the engine is operating.

8.33 Never hold the hydraulic controls in their extreme position after the
equipment has reached its maximum travel. This could result in
overheating of the hydraulic system.

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8.34 Do not leave the machine with the load on the hook raised above the
ground.

8.35 Always keep safe distance from a heavy equipment/ Pipe-layer while it is
operating. Don’t be in its way when it is not working. Don’t go to sleep
under its ample shade no matter how hot the sun. Don’t distract the
attention of the operator. Keep in view and communication of the operator
if you are working with him. If you are not working with him flag him
when you get in range and flag him when you get out.
8.36 Be aware that Pipe-layer in operation can be lethal if out of control. The
operator on whose finger tips the control/ power resides may not be able to
notice your presence, or may misjudge your intended steps; that could
result in an unintended and uncontrolled unleashing of destructive power
having catastrophic consequences such as reversing of equipment onto
you, bringing close in the striking range of the boom or the counter
weight, or getting caught/ trapped between a tree and the rotating
structure. Therefore, always STOP or raise a flag and make contact with
operator before coming in working range of the machine.

8.37 While handling pipes during stringing, welding or lowering etc. activities
always ensure that Pipe is an unstable weight, and it can be hazardous if
roll on from a height in case not properly secured. Always ensure that pipe
should be stacked and kept in place by stops. These stops may be in the
shape of contoured bolsters, wedges, or plain stops. Pipe will not be
handled without an assessment of adequate stop against roll.

8.38 Do not rush. Hurrying can lead to accidents.

8.39 Do not jump on or off the machine.

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