Guidance on the selection and training of offshore crane drivers
1. Introduction
Accidents and incidents involving offshore cranes continue to be reported to the Department of Energy each year. As the crane plays a crucial role in the offshore petroleum industry, the effective selection and training of crane drivers is of vital importance.
2. Scope
The variety of lifting operations undertaken offshore is reflected in a wide range of lifting machines, which are in use. Many of these are referred to as “cranes”, but this is a term which includes machines of such disparate design and construction as, for example, overhead travellers and the extremely heavy lifting cranes associated with crane barges.
The training of the drivers of all such “cranes” will have common elements. However, this guidance is directed specifically at the selection and training of the drivers of conventional jib cranes with a boom length in excess of 6 metres and a maximum safe working load of no more than 250 tonnes. Such cranes undertake a wide variety of lifting work, from deck operations to the unloading and back loading of supply vessels.
3. Legal Aspects
The main legal requirements relevant to crane drivers are contained in the Offshore Installations (Operational Safety, Health and Welfare) Regulations 1976 (ST 1019). In particular, crane drivers are required to be competent, or work under the close supervision of such a person. General requirements relating to systems of work and training are also contained in the Health and Safety at Work Act 1974.
Details of all the relevant legislation are contained in Annex 1.
4. Selection of Crane Drivers
A person undergoing training should:
(i) Have a level of ability to enable him to absorb the training criteria described in the next sections
(ii) Have an ability to read, understand fully, and apply the information contained in operating manuals and instructions
(iii) Have the ability to cope with emergencies and also to work alone.
5. Duties of a Crane Driver
Depending on the crane and the working procedures adopted, a crane driver may be required to undertake a variety of duties in respect of the cranes for which he has been trained. Whatever his overall duties may be, he will require to have:
(i) An understanding of the safe working practices applicable to offshore crane operations
(ii) Knowledge of the working parameters of the crane he is required to operate, including the fitted safety devices
(iii) Knowledge of and the ability to act on the signals used in crane operations.
(iv) A working knowledge of safe slinging practices
(v) Sufficient working knowledge of the crane to enable him to carry out routine inspection of the crane, including the boom and ropes, before allowing lifting operations to commence
(vi) An adequate understanding of the relevant requirements.
6. Training
The training of a crane driver should be a stage 4 exercise, including both theory and practice. These stages are:
(i) Working offshore with a crane driver who is both trained and experienced with the crane in use;
(ii) A course which includes the principle aspects of crane operations;
(iii) A course which provides training in the operation of cranes in all reasonable operating conditions together with, where practicable, information on the type(s) of crane to be operated by the person offshore;
(iv) Practical instruction offshore in control techniques, potential dangers, driver maintenance procedures and safety instructions relevant to the types of cranes to be operated by him.
There may be circumstances where the proven abilities of a candidate are such that he can proceed directly to stage (iii) of the training. Whatever a persons abilities however, prior to his first appointment offshore as a competent crane driver he should receive training to the standards outlined at stages (iii) and (iv).
During stages (iv) there should be a practical assessment of the persons abilities to a satisfactory performance level prior to the formal appointment as a competent crane driver.
A crane driver who is required to operate any other type of crane on which he has not demonstrated a satisfactory performance assessment should undergo and successfully complete a practical assessment as in stage (4).
Annex 2 outlines the minimum requirements recommended for each stage of the training.
Training Requirements Stage 1
Aim
The aim of this stage is to give prospective crane drivers experience of working offshore with a crane driver who is both trained and experienced with the crane in use. It should be sufficiently long to assess the individuals potential as a crane driver, and should confirm his ability to operate communication systems and understand adequately radio instructions.
Training Requirements - Stage 2 (4/5 day course)
Aim of the course
To provide an understanding of the principles of crane operations.
Course Content
Theory
1. Identification of crane types and the general principles of construction, with identification of major parts.
2. Terminology used in crane operations.
3. Principles of stability.
4. Principles of safe working loads including:
(i) Definition
(ii) Limitations of load/radius combinations
(iii) Capacity charts
(iv) Measuring radius
(v) Factors affecting lifting capacity.
5. Safe working load indicators – their use, operations and limitations.
6. Other safety devices including, boom, hoist and unwing limiting devices, rig savers and emergency stops.
7. An introduction to ropes and lifting tackle in use offshore including wire ropes and chain slings, shackles, lifting eyes, spreaders, pallet bars, pipe hooks etc and cargo nets. This should include information on rope drums and pulleys, anchorages, bulldog grips, rope reeving and inspection.
8. Introduction to slinging, banking and the use of lifting tackle to include:
(i) Crane signals
(ii) Lifting equipment and typical loads
(iii) Correct use of slings
(iv) Methods of slinging
(v) Correct use of other lifting tackles
9. Principles of operation and maintenance:
(i) Theory of main movements and controls
(ii) Pre-operational checks
(iii) Checks during operation
(iv) Shut-down procedures
(v) General maintenance requirements
10. Major dangers and types of accident.
11. Duties and responsibilities.
12. Legislation relating to crane, lifting tackle and the duties of crane drivers.
(i) Offshore Installations (Operational Safety Health and Welfare Regulations 1976 (SI 1019)
(ii) Health and Safety at Work Act 1974
Practical
(i) Pre-start checks
(ii) Start-up procedures
(iii) Pre-operational checks
(iv) Use of controls
(v) Shut down procedures
(vi) Co-ordination exercises
(vii) Development of control skills
Training Requirements - Stage 3 (4/5 day) Assessment
Aim of the course
To provide participants with sufficient skills and knowledge to progress to the operation offshore of cranes.
Course contents
Theory
1. Crane types.
2. Crane design and constructions:
(i) Structural limitations
(ii) Transmission types
(iii) Control systems
(iv) Speed and power limitations
(v) Simple mechanics applicable to cranes
(vi) Safety devices
3. Crane operations:
(i) Appreciation of possible alternative control techniques
(ii) Pre-operational checks
(iii) Checks during operation
(iv) Possible emergency procedures
(v) Practical problems
(vi) Appreciation problems
(vii) Appreciation of nautical terminology relevant to crane operations
4. Wire ropes
(i) Their construction specifications
(ii) Inspections and tests
(iii) Wear and deterioration
(iv) Types of examination schemes
5. Lifting tackle:
(i) Wire, chain and fiber rope slings
(ii) Shackles
(iii) Lifting eyes
(iv) Spreaders
(v) Pallet bars
(vi) Pipe hooks and specialist equipment
(vii) Construction specifications
(viii) Inspection / test, wear and deterioration
(ix) Types of examination schemes
(x) Use of cargo nets
6. Loads including weight estimation and conversion.
7. Lifting of personnel basket.
8. Services and support vessels:
(i) Check loading and securing
(ii) Impacts, loads and effects
(iii) Cargo types and identification
(iv) Mooring principles
(v) Handling bulk cargo hoses
9. Maintenance
(i) Principles of regular servicing
(ii) Logs and records
10. Crane related hazards of the offshore environment including discussion on causation and prevention of accidents.
11. Legislation including reiteration of the requirements, obligations and duties as for stage 2.
Practical
(i) Pre-operational checks
(ii) Visual inspection, essential adjustments
(iii) Operational checks
(iv) Function tests
(v) System checks
(vi) Control checks
(vii) Shut down methods
(viii) Crane out of services procedures
(ix) Post operational procedures
(x) Use of personnel basket
(xi) Operating skills with exercises to increase co-ordination and to create a specific realisation of crane limitations with discussion on emergencies and the appropriate remedial actions.
Training requirements – stage 4 (3 day) assessment
Aim of the course
Training offshore with the cranes to be used by the candidate, under supervision and with final assessment.
Course contents
Operation of the crane or cranes covering all aspects of use including the techniques and the dangers together with full instruction and evaluation of all fitted safety devices.
Wherever possible operation under differing weather conditions should be under taken.
Assessment
In the final assessment the candidate will be expected to perform safely and satisfactorily any crane operations, which have been previously demonstrated. Instructors or other persons carrying out this final assessment should themselves be trained, experienced crane drivers familiar with the crane used by the candidate.
Legal Requirements Relevant to Crane Operations
A. The offshore installations (operational safety, health and welfare) regulations 1976, SI No 1019
Regulation 7
Written Instructions
7 (1) There shall be provided in respect of every offshore installation by the owner of the installation written instructions specifying practices to be observed to ensure the safety of the installation and the safe use of the equipment thereon.
(2) Any written instructions provided under paragraph (1) above shall include provisions relating to the matters specified in schedule 2 to these regulations.
(3) The owner of an offshore installation shall, upon demand, furnish to the Secretary of State a copy of the written instructions provided in respect of the installation under paragraph: (1) above.
(4) If the Secretary of State is of the opinion that any written instructions provided in respect of an offshore installation under paragraph (1) above do not make sufficient provision to ensure the safe use of the equipment of the installation and safety in carrying out all operations on the installation, he may serve on the owner of the installation a notice in writing stating that he is of that opinion and specifying the matter for which, in his opinion, provisions or, as the case may be, different provision ought to be made and the nature of the provision that, in opinion, ought to be made, and the owner of the installation shall, before the expiration of such period beginning with the date of services of the notice as may be specified therein, amend the written instruction accordingly.
(5) A notice for the purpose of paragraph (4) above shall be sufficiently served on the owner of an offshore installation be addressing it to him and delivering it to him or sending it by post addressed to him at the last address in the United Kingdom notified for the purposes of Regulations 5(1)(a) or (b) of the Offshore Installations (Registration) Regulations 1972 (a).
(6) It shall be the duty of every installation manager to ensure that the activities of any person engaged in any operation or work on, from or in connection with an offshore installation are carried out in accordance with the written instructions provided in respect of the installation under paragraph (1) above and that the relevant part of the written instructions is brought to the attention of every such person.
Regulation 30
Operational Staff
30 (1) There shall be provided on every offshore installation a sufficient number of competent persons appointed by the installation manager to be responsible for the control and safety of:-
(a) The structure of the installations
(b) The electrical equipment of the installation
(c) The mechanical equipment of the installation
(d) Lifting appliances and lifting gear
(e) Drilling operations
(f) Production operations
(g) The handling and storage of acids, caustic alkalis, explosives, radioactive and other dangerous substances and
(h) Any other unusual or dangerous operations
and the installation manager shall ensure that a list of all such persons on the installation is maintained on the installation at a place where it can be conveniently read by persons on the installation.
(2) Every person who uses any equipment (other than domestic equipment) or who is engaged in carrying out any operation (other than an operation of a domestic nature) on or near an offshore installation shall either:
(i) Have experience of and be competent to use that equipment or have experience of and be competent to be engaged in that operation; or
(ii) Work under the close supervision of a person who has experience of and is competent to use that equipment or who has experience of and is competent to be engaged in that operation as the case may be.
Regulation 32 (Part)
Duties of persons
31 (1) It shall be the duty of the installation manager, and of the owner of the installation and of the concession owner, to ensure that the provisions of these Regulations and complied with in respect of any offshore installations.
(3) It shall be the duty of the employer of an employee employed by him for or near an offshore installation to ensure that the employee complied with any provision of these Regulations imposing a duty on him or expressly prohibiting him for doing a specified act.
(4) It shall be the duty of every person while on or near an offshore installation:-
(a) Not to do anything likely to endanger the safety or health of himself or other persons on or near the installation or to render unsafe any equipment used on or near it;
(b) To co-operate with his employer, if employed, and any other person on whom a duty or requirement is imposed by these Regulations so far as is necessary to enable that duty or requirement to be performed or complied with; and
(c) To report immediately to the appropriate responsible person or, if no such person be appointed or, if appointed, unavailable, to the installation manager and defect in any equipment which appears to him likely to endanger the safety, health or welfare of persons on or near the installation or the safety of the installation and any equipment used with it.