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LIFTING PLAN 0002 Rev 0A Procedure / Work Instruction / Job Note Page 1 of 15 LIFTING PLAN 0002 Rev 0A Procedure / Work Instruction / Job Note Page 2 of 15 TABLE OF CONTENTS 1. Introduction 4 1.1 Purpose 4 1.2 Scope 4 2. Roles and Responsibilities 4 2.1 Construction / Installation Engineer 5 2.2 HSE...

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LIFTING PLAN Procedure / Work Instruction / Job Note

0002 Rev 0A Page 1 of 15

LIFTING PLAN Procedure / Work Instruction / Job Note

0002 Rev 0A Page 2 of 15

TABLE OF CONTENTS 1. Introduction 1.1 Purpose 1.2 Scope 2. Roles and Responsibilities 2.1 Construction / Installation Engineer 2.2 HSE Officer 2.3 Lifting Operation Work Leader 2.4 Crane Operator 2.5 Safety Standby 2.6 Rigger / Signaller 3. Lift Planning and Execution 3.1 Safe System of Work 3.2 Planning 3.2.1 Assessing the lifting operation hazards 3.2.2 non – routine lifting operation 3.2.3 Lifting Study 3.3 Execution 3.3.1 Communication of lifting plan 3.3.2 Conducting the lifting operation 3.3.3 Moving the load 3.4 Reacting and Changing Conditions 3.5 Learn and Record 4. Application and Step Out Approval 4.1 Application 4.2 Step Out Approval Appendix A – Job Safety Analysis Appendix B – Manual Book SANY Crawler Crane SCC1000C 100 Tones Appendix C – Drawing of GEG Installation Using Mobile Crane 127 Tones Appendix D – Lifting Study Appendix E – Crane Inspection Report Appendix F – GEG Drawing and Packing List and Lifting Gear Certification

4 4 4 4 5 5 5 6 6 6 6 6 7 7 7 8 8 8 8 9 9 9 9 9 9 10 11 12 13 14 15

LIFTING PLAN Procedure / Work Instruction / Job Note

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1.

Introduction In order to provide a safe system of work and to ensure compliance with current legislation this site lifting plan has been developed and is to be implemented by every member of the crane team involved with GEG Installation project. Although not exhaustive the following regulations must be adhered to:  The Occupational Health and Safety Regulation of Indonesia No. 1 / 1970  The Labour and Transmigration Minister Regulation of Indonesia about Lifting Activities (PER.09/MEN/VII/2010)  The Labour and Transmigration Minister Regulation of Indonesia about lifting Equipment (PER.05/MEN/1985)  COPI Lifting Procedure (ID-G-BU-00000-00000-00403)  COPI Lifting Equipment Certification Procedure (IDG-BU-00000-00000-00315)  COPI Crane Procedure (ID-G-BU-YH0-PRO-GN-00-0009)  KPI Manual Handling & Lifting Procedure (F038-12-CON-PRC-001) It is vital that all lifting operations are properly planned by a competent person and that the plan is followed by everyone involved in the operation. This plan is to be read by all team members involved in lifting operations; this must be done prior to any lifting being carried out. It is essential that all team members are fully competent and certified to carry out their individual roles. It is essential that all team members are confident that they can fulfil their duties especially when works may need to be carried out at height. 1.1 Purpose This document provides the procedure to be used for crane operational for GEG Installation at Rawa Power Plant. The key to safe crane operation is having qualified personnel using the correct equipment in a safe manner. This procedure will outline the issues relating to the selection of the correct people for the task. It will describe the operational of Lifting and rigging task to be used by these people as part of a safe and effective crane and rigging program. 1.2 Scope This procedure applies to lifting operations of GEG Installation in Rawa Power Plant. The lift planning process describes the systematic assessment of important load factors and site factors. It is as applicable to ”heavy” non-routine lifts. Planning a non-routine lift requires considerable effort. In a lift determined to be complicated non-routine lift, many of the elements can be determined "by inspection"; and the depth involved in a nonroutine lift will be required. However, the planning process must be followed. This procedure prohibits a person from riding or travelling on the load, lifting hook, sling, as built facilities or other lifting medium.

2.

Roles and Responsibilities When appointing a crane team it is essential that all the members of that team are fully aware of the role and duties and that each person has sufficient knowledge, training and experience to carry out their role. Records of training and experience are to be verified prior to any new member joining the crane team and their details are to be retained in the site file by reviewing certification of skilled labours.

LIFTING PLAN Procedure / Work Instruction / Job Note

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The lifting operation team organization chart is shown below and roles and duties are continued beneath.

HSE Officer

Construction / Installation Engineer

HSE Standby

Lifting Operation Work Leader

Rigger/Signaler

Crane Operator

2.1 Construction / Installation Engineer The Construction / Installation Engineer’s duties are to include the following:  Assess the lifting operations to provide such planning, selection of cranes, lifting accessories and equipment, instruction and supervision as is necessary for the task to be undertaken safely. (where works are on a shared site or where logistics may be restrictive co-ordination with others will be required)  Ensure that adequate equipment and tools for lifting process have been completed prior to its use.  Establish an effective procedure for reporting defects and incidents and taking necessary corrective action  Ensure the crane operator, work leader and riggers/signallers are fully briefed in the contents of the lift plan / method statement etc 2.2 HSE Officer The HSE Officer’s duties are to include the following:  Being familiar with the relevant parts of the project Health and Safety Plan where lifting operations are to be carried out on a site where COPI regulations apply.  Ensure that adequate inspection / examination and maintenance of the equipment have been carried out prior to its use.  Establish an effective procedure for reporting defects and incidents and taking necessary corrective action.  Takes responsibility for the organisation and control of the lifting operation.  Ensure the crane operator, work leader and riggers/signallers are fully briefed in the contents of the lift plan / method statement etc. The appointed person is able to delegate his duties to another person but the responsibilities still remain the appointed persons. 2.3 Lifting Operation Work Leader  The Lifting Operation Work Leader role is to direct and supervise the lifting operation and ensure that these are carried out in accordance with the relevant method statement / lift plan.  The Lifting Operation Work Leader should be competent and suitably trained and must be experienced to carry out all relevant duties.  The Lifting Operation Work Leader has authority to stop the lifting operation if he considers it dangerous to proceed. This role can be carried out by the appointed person or may be delegated to someone with appropriate expertise in lifting operations.

LIFTING PLAN Procedure / Work Instruction / Job Note

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2.4 Crane Operator  The crane operator is responsible for the correct operation of the crane in accordance with the manufacturer’s instructions and within the safe system of work.  The crane operator is to respond to a single rigger / signaller at any given time and these must be identifiable to the operator.  If there is any person near a lifting operation give the recognised stop signal the operator must cease lifting operations immediately and confirm what actions are required from the rigger / signaller.  The crane operator must report any defects to the appointed person immediately. (The driver may report defects direct to the fitters but the appointed person must still be made aware of this action) 2.5 Safety Standby / Safetyman  The HSE Standby controls the lifting operations to provide safely lifting activities.  The HSE Standby has authority to stop the lifting operation if he considers it dangerous to proceed. 2.6 Rigger / Signaller  The rigger / signaller is responsible for the attaching and detaching of loads to and from the crane load lifting attachment and ensuring that the correct accessories are used for that operation in accordance with the planning of the operation.  The rigger / signaller are responsible for the safe movement of the crane and clear direction must be given whether visual or hand signals.  Where more than one rigger / signaller is required, clear instruction must be given when passing responsibility over to the next rigger / signaller.  The rigger / signaller is to store lifting accessories in a suitable place when not being used and prior to re-using an accessory he must visually inspect it before use.  The rigger / signaller must notify the appointed person of any damaged equipment immediately. 3

Lift Planning and Execution 3.1 Safe System of Work Whether the lifting operations are repetitive or if they are a one off, a safe system of work must be established and followed for the operation to be both safe and successful. In order to provide a safe system of work the following items are to be included in the lift plan / Assessment:  The selection of suitable cranes and work equipment must be carried out.  A crane team is to be employed who are fully trained and competent and who have had their roles and responsibilities clearly explained to them.  The areas for the cranes access and rigging etc must be properly planned and properly prepared.  A regime of maintenance, testing and examination of equipment must be devised.  All certification, reports of thorough examination and other documents including manufacturer’s manuals are to be retained and be available. It is essential that all personnel can communicate clearly in the same language and communication tools (Walkie – Talkie) should be provided for lifting team. When a lifting operation has to be carried out, it has to be checked if this particular lifting operation has been carried out before on that site. A risk assessment and Lift Plan might already exist. If a risk assessment and Lifting Plan do exist then they shall be assessed to confirm that they are still applicable (e.g. changes to personnel, equipment, and site layout or work environment could all result in the need for re-assessment of hazards). Assuming

LIFTING PLAN Procedure / Work Instruction / Job Note

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that significant changes have not taken place then lifting operations may proceed under the requirements of the Lift Plan subject to approval by the lifting engineer. If the lifting operations have not been carried out before, a competent person will prepare a Lifting Plan. This has to be initiated by the executing department. To define the lift the following parameters are established:  Load weight, shape, centre of gravity and availability of adequate lifting points (Described in Appendix C - Drawing of GEG Installation Using Crane 100 tonnes)  Initial and final load positions and how it will get there (Described in Appendix B & C - Drawing of GEGInstallation Using Crane 100 tonnes)  The environment in which the Lifting Equipment will be used (Described in Appendix A - JSA for GEG Installation) 3.2 Planning 3.2.1 Assesing the lifting operation hazards For every lifting operation the risks have to be assessed and controlled. KPI will be carried out Job Safety Analysis (JSA) prior to any lifting operation to identify associated hazards, their hazard risk level should be reduce until it is safe for work. The Job Safety Analysis (JSA) format are shown in the Appendix A. The assesing the risks of hazards will be included the following aspects and activities:  Cultural, communication and language difficulties  Weight, size, shape and centre of gravity of load  Availability of approved lifting points on load  Method of slinging/attaching/detaching the load  Overturning/load integrity/need for tag lines  Suitability and condition of Lifting Equipment to be used  Initial and final load positions and how it will get there  Ground and underground considerations  Lifting over live equipment  Number and duration of lift(s)  Conflicting tasks in area  Environmental conditions including weather and permissible limits  Lighting in the pick-up and lay-down areas  Proximity hazards, obstructions, path of load (e.g. potentially live electrical, hydraulic or pneumatic lines, underground conduits, bridges and overhead structures)  Working under suspended loads  Access and emergency escape routes for the Lifting Appliance Operator and load handlers (e.g. Rigger, Slinger)  Experience, competence and training of personnel  Number of personnel required for task  Pre-Use Inspection of equipment by Operator  Visibility of the load at all times by either the Lifting Appliance Operator or the person guiding the load (Rigger). He must maintain communication with the Operator at all times either via hand signals, radio or a relay Signal Rigger. 3.2.2 Non-Routine Lifting operations As an aid to identifying risks and suitable controls, GEG Installation will be categorized as complicated non-routine lifting operation. The control requirements for complicated non-routine lifting operation are as follows: Non-Routine – Complicated when:  Gross load is greater than 25 tones, or Gross load represents more than

Documentation/Controls  Lifting Plan  Job Safety Analysis  Work Permit

Competent Personnel  Construction / Installation Engineer  HSE Officer

LIFTING PLAN Procedure / Work Instruction / Job Note

0002 Rev 0A Page 7 of 15

75% of the load chart at working radius, or Gross load is greater than 30 tones and is also greater than 80% of the manufacturer’s load chart  Continuation of a lifting operation with different equipment (due to malfunction, inadequacy or unsuitability)  Use of two or more Lifting appliances (tandem lifting)  Within sensitive, difficult or restricted areas

      

Safety checklist Toolbox Talk Lifting procedure Specific calculation of load Lifting Method and Step of Lift Layout area of lifting operation Report of Crane capabilities inspection  Certification of overall crane functioned part from third party and goverment

 Lifting Operation Work Leader  Safety Stand by  Crane Operator  Signaler  Slinger / Rigger

3.2.3 Lifting Study The Lifting Study of GEG Installation will be included following items:  The competent person planning the lift  Calculations  Equipment Capabilities  Personnel required and their particular roles  Step-by-step instructions  Communication methods to be used  Contingency and rescue plans A sample Lifting Study is described in Appendix D. 3.3 Execution 3.3.1 Communication of Lifting Plan Prior to starting of lifting operations a competent person shall hold a Toolbox Talk with all personnel assigned to carry out the lift. The Person-in-Charge (PIC) shall be clearly identified and made known to all members of the lift team and personnel in the proximity. All personnel involved in the lifting operation shall have their individual responsibilities clearly allocated. All personnel should have the opportunity to review the findings of the risk assessment and the details of the Lifting Plan to ensure that everyone clearly understands and agrees with the methods and control measures to be used. (Details described in Appendix D - Lifting Study Form) 3.3.2 Conducting the Lifting Operation  Lifting operations shall be conducted in strict accordance with the approved Lifting Plan.  Any variation from the agreed Lifting Plan shall result in the job being stopped and reassessed to ensure continued safe operation.  The Carne Operator shall obey an emergency stop signal at all times, no matter who gives it.  When lifting operations need to be controlled by signals, a designated signal person shall be assigned. Signals between the Crane Operator and the designated signal person (Rigger / Signaler) shall be audible or visible at all times.  The appropriate load-radius chart for the Lifting Appliance configuration in use shall be visible to the operator.  Load to be lifted shall be confirmed to be within the rated capacity of the Lifting Equipment and attached by means of suitable Lifting Accessories.  The Crane Operator shall not leave the operating controls while the load is suspended. 3.3.3 Moving the Load

LIFTING PLAN Procedure / Work Instruction / Job Note

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 Prior to lifting the PIC shall be satisfied that the load is secure and properly balanced and that the load path is clear of obstructions and personnel  At commencement of the first lift the Crane Operator shall carefully check the operation of the hoist brake to ensure no slippage occurs  Take up sling slack to confirm that the Crane hook has been positioned centrally over the load lifting point, adjust the Lifting Equipment as necessary to minimize any ‘drift’ of the load as it is lifted  No external forces shall be applied to the load that create significant side loading of the Lifting Equipment  For crane operations appropriate tag lines shall be used to control the load – large or long loads with flat sides that could act as a ‘sail’ are particularly prone to spinning and tag lines shall be used – tag lines shall be secured to the load and not to the rigging slings  Cranes shall not be used for dragging a load Additional requirements, specific to particular equipment or operations, are detailed in Appendix E – Crane Inspection Report. 3.4 Reacting and changing conditions All critical lifting parameters (e.g. weather, sea state, visibility, terrain stability and slope, surrounding operations and installations, site access and egress, Lifting Equipment, personnel) shall be identified during the risk assessment and preparation of the Lifting Plan. The PIC shall ensure that these conditions are monitored as lifting operations proceed to ensure continued safety. If, as part of the operation and maintenance of equipment, the computer system shuts down the operation, the load must be placed on the ground and a new lift plan must be developed, eliminating the condition that caused the shut down. Procedures for recovering and landing the load in the event of the lift being aborted shall be clearly identified. 3.5 Learn and record After completing the lifting operation, everyone involved in the lift should have the opportunity to discuss and make improvements to the Lifting Plan. Any learning points noted on the plan must be reviewed by a competent person and, where appropriate, action taken. Learning points may include feedback on equipment effectiveness, lifting techniques, personnel, etc. 4

Application and Step Out Approval 4.1 Application This Lifting Plan is only applicable to GEG Installation at Rawa Power Plant (COPI facilities). As such, this document is mandatory and shall be adhered to by all parties, involved in lifting operations. 4.2 Step out Approval Any step-out from this plan shall be addressed to the Construction / Installation Engineer in writing. He will review and authorize the deviation in exceptional circumstances.

LIFTING PLAN Procedure / Work Instruction / Job Note

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Appendix A Job Safety Analysis Report

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Appendix B Manual Book SANY Crawler Crane SCC1000C 100 Tones

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Appendix C Drawing of GEG Installation Using Mobile Crane 127 Tones

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Appendix D Lifting Study

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Appendix E Crane Inspectio...