PROVIDE SERVICE FOR INSTALLATION ONE

PROJECT NAME FREE SEPARATOR AND CONNECTION STEAM

EXCHANGER PIPELINE PROJECT

PROJECT NO. 023-SO-20-EBS

DOCUMENT NAME Lifting Plan of One Free Water Separator
DOC NO. EBS-023-YOSC-HSE-002 Page no. Page 1 of 14

Lifting Plan of One Free Water Separator

 Lifting Plan of One Free Water Separator Installation

Contents
1. PURPOSE ............................................................................................................................................................ 2

2. SCOPE ................................................................................................................................................................. 2

3. REFERENCES .................................................................................................................................................... 2

4. PREREQUISITES............................................................................................................................................... 2

4.1 REQUIRED PERSONNEL ...................................................................................................................................... 2

4.2 PREPARATION OF TOOLS AND MACHINES.......................................................................................................... 2

4.3 TECHNICAL DOCUMENTS .................................................................................................................................. 2

4.4 SITE CONDITION ................................................................................................................................................ 2

5. PROJECT OVERVIEW ..................................................................................................................................... 3

5.1 BASIC INFORMATION OF FREE WATER SEPARATOR .......................................................................................... 3

5.2 LIFTING METHOD .............................................................................................................................................. 3

5.3 TABLE OF LIFTING PARAMETER FOR 100 T CRANE ........................................................................................... 3

6. DETAILS ............................................................................................................................................................. 4

6.1 CHECK PREREQUISITE ....................................................................................................................................... 4

6.2 REMOVAL OF FREE WATER SEPARATOR ........................................................................................................... 4

6.3 TRANSPORTING FREE WATER SEPARATOR TO DESIGNATED PLACE AND UNLOADING ....................................... 4

6.4 LOADING OF FREE WATER SEPARATOR AND TRANSPORTING ............................................................................ 4

6.5 LIFTING OF FREE WATER SEPARATOR ............................................................................................................... 5

6.6 EQUIPMENT ADJUSTMENT ................................................................................................................................. 5

6.7 WORKING SITE CLEANING ................................................................................................................................ 6

7. HSE REQUIREMENTS ..................................................................................................................................... 6

8. APPENDIXES ..................................................................................................................................................... 7

8.1 APPENDIX 1： FORCE CALCULATION ................................................................................................................ 8

8.2 APPENDIX 2：VERTICAL VIEW FOR LIFTING .................................................................................................. 10

8.3 APPENDIX 3：LIST OF MAIN TOOLS AND MACHINES ...................................................................................... 11

8.4 APPENDIX 4： CAPACITY SHEET OF CRANE 100 T .......................................................................................... 12

8.5 APPENDIX 5： CONSTRUCTION ORGANIZATION CHART ..................................................................................... 13

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 Lifting Plan of One Free Water Separator Installation

1. Purpose
This plan mainly describes the Lifting and installation of one free water separator in S1 in East
Baghdad oil field, define the construction process, quality and safety precautions of separator lifting,
and standardize the site construction.
2. Scope

This plan just applies to the lifting and installation of one free water stage separator in S1 at East
Baghdad Oil Field. Main construction activities include lifting, unloading, transportation,
equipment adjustment etc. of the separator.

3. References
API RECOMMENDED PRACTICE 686
SH/T 3536-2011
Lifting Construction Specification for Petrochemical Engineering
SH/T 3515-2003
Construction Standard for Large-size Equipment Hoisting Engineering
4. Prerequisites
4.1 Required Personnel
1) Construction staff shall pass the relevant training and the safety education;
2) Before construction, staff shall attend the construction safety and technical disclosure;
3) The staff involved in lifting work shall be familiar with lifting process, well know his job
responsibility, and obey the command;
4) Signal of lifting work is clear between lifting commander and crane driver.
4.2 Preparation of Tools and Machines
1) Tools and machines are complete, with required quantity;
2) Crane is with good working condition; its inspection is qualified;
3) Shackles, slings and other major tools and machines are inspected as qualified;
4) See appendix 5 for major equipment, tools and machines required for construction.
4.3 Technical Documents
1) Lifting plan and JSA of free water separator has been issued.
4.4 Site Condition
1) The ½” pipe affecting the entry and exit of crane and transportation trailer has been
removed;
2) Check the equipment transportation road along the equipment transportation route is
without any obstacle, the turning radius at turning area meets the requirement, the clear

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 Lifting Plan of One Free Water Separator Installation

height at height limit area meets the equipment transportation requirement;

3) The ground where the crane stands has been leveled and compacted, meeting the lifting
requirement;
4) Lifting work shall be performed when wind speed is less than 10.8m/s, without heavy rain
and sandstorm.
5. Project Overview
5.1 Basic Information of Free Water Separator
The Free Water separator mainly consists of the storage tank body and supports. The weight of
the storage tank is 10 tons with external dimension φ2500mm×12000mm, the supports assembly
weighs about 2 tons.
5.2 Lifting Method
The Free Water separator shall be lifted mainly by using a mobile crane 100 T and transported
by low bed trailer 30t.
5.3 Table of Lifting Parameter for 100 T Crane

Total Max.
Rigging Crane Rated Load
Item to be Weight Lifting Working
No. Weight Working lifting Rate
Lifted (t) Weight Radius
(t) Condition weight(t) （%）
(t) （m)

Free Water Main boom

1 separator 12 1 13 11 21.5 83.8
body 20.2m

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 Lifting Plan of One Free Water Separator Installation

6. Details
6.1 Check Prerequisite
Check the Free water separator is ready for removal and lifting as per SECTION 4: Prerequisites.
Verify site condition before lifting, ensure travelling path of crane and trailer is clear.
6.2 Removal of Free Water Separator
1) The 100 T crane shall enter the designated location on the construction site, pay attention
that the front part of the crane does not collide with the access facilities on site.
2) By forklift or manual handling, place four road base plates under the crane outriggers.
3) Load the crane with all its own counterweights, adjust the main boom of the crane to 20.2M.
4) Connect the sling for equipment lifting as shown in appendix 4, protect slings with rubber
etc. to prevent slings to be damaged, and tie anti-swing ropes on both ends of the equipment.
After connecting the sling, raise the hook so that the sling is slightly stressed.
5) Tie anti-swing ropes on both ends of equipment to control the direction during lifting.
6) After sling is connected, remove the equipment connection bolt. Lift the equipment up 200-
300mm away from the platform for trial lifting. Check whether the equipment is balanced,
lifting device, slings, crane brakes and ground is normal or not.
7) After the trial lifting is qualified, the Free Water separator shall be lifted by operations such
as rotation, luffing etc. onto the transportation trailer for loading (should use the low bed
trailer).
6.3 Transporting Free Water Separator to designated place and Unloading
1) After the equipment is loaded, fix the equipment on truck by using 3 sets 5T chain blocks.
2) Special person shall be arranged to guide the truck, driving speed no more than 30km/h.
3) Ensure that the safety distance of the top of the device from the high voltage cable (if any)
is greater than 1.1m.
4) After the equipment is transported to designated place, unload the equipment as per the
steps in Section 7.2.
6.4 Loading of Free Water Separator and transporting
1) The 100 T crane shall enter the designated location on the lifting site.
2) By forklift or manual handling, place four road base plates under the crane outriggers.
3) Load the crane with all its own counterweights, adjust the main boom of the crane to 20.2M.
4) Connect the sling for equipment lifting as shown in appendix 4, protect slings with rubber
etc. to prevent slings to be damaged, and tie anti-swing ropes on both ends of the equipment.
After connecting the sling.

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 Lifting Plan of One Free Water Separator Installation

5) Tie anti-swing ropes on both ends of equipment to control the direction during lifting.
6) After sling is connected, Lift the equipment up 200-300mm away for trial lifting. Check
whether the equipment is balanced, lifting device, slings, crane brakes and ground is normal
or not.
7) After the trial lifting is qualified, the Free Water separator shall be lifted by operations such
as rotation, luffing etc. onto the transportation trailer for loading
8) Pay attention to the nozzle orientation when loading.
9) Fix the equipment on truck by using 3 sets 5T chain blocks.
10) Before equipment transportation, check again whether the equipment transportation route
is without any obstacle.
11) Special person shall be arranged to guide the transportation trailer.
12) The vehicle driving speed shall be no more than 30km/h.
6.5 Lifting of Free Water Separator
1) The crane shall enter its standing location in construction area. Place four road base plates
under the outriggers and install the counterweights of the crane itself. Check if there are
obstacles at 4 meters from the center of the crane.
2) The transportation trailer shall enter the construction site.
3) Confirm again the orientation of equipment nozzle before equipment positioning.
4) Connect the sling for equipment lifting, protect slings with rubber etc. to prevent slings to
be damaged, and tie anti-swing ropes on both ends of the equipment. After connecting the
sling, raise the hook so that the sling is slightly stressed.
5) Remove the chain blocks that fix the equipment on the transportation trailer.
6) Working condition of crane: Main boom of the 100 T crane is 20.2m, with total
counterweight. Working radius shall be no more than 11m.
7) Lift the equipment up for 200-300mm away from the trailer for trial lifting. Check whether
the equipment is balanced, lifting device, slings, crane brakes and ground is normal or not.
8) If the trial lifting is qualified, drive the trailer away.
9) The crane shall lift the Free Water separator onto the platform by operations such as
rotation and luffing etc. Pay attention to keep the safe distance between the equipment and
crane body during lifting.
10) After equipment is positioned, remove the lifting device and slings.
6.6 Equipment Adjustment
1) Adjust the position, elevation and horizontal of equipment after it is positioned, ensure the

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 Lifting Plan of One Free Water Separator Installation

position, elevation and horizontal of equipment meet requirements.

2) Steel plate can be added to adjust the horizontal of equipment.
6.7 Working Site Cleaning
1) After the lifting is finished for a day, clear up lifting device, slings, and sleepers. Achieve
civilized construction.
2) It requires on site that clean working site after daily work finished in time.
7. HSE Requirements
1) All staff involved in construction shall be trained for safety. Strictly follow the safety
regulations and post safety rules, do not command and work against rules. Do not violate
work rules.
2) Be careful when working in the production area to avoid damaging the items already
installed on site.
3) Define precautionary area for lifting work. Make sure both construction work and staff are
safe. Only authorized personnel can get in the precautionary area.
4) Conduct JSA before construction.
5) Get relevant permits before construction.
6) Every group worker must take gas detector.
7) Workers involved in lifting work shall be trained. He can perform the work only after his
training is qualified. Workers for special type of operation shall have the certificates.
8) Group leader shall carry out the compliance inspection of working site before lifting. If any
unsafe factor is found, feedback and solve it immediately.
9) To perform all construction work, people shall comply with the procedure strictly and
prevent the equipment from damage caused by improper operation.
10) Workers involved in lifting work shall follow the Construction Regulations of Lifting Work
Safety.
11) All staffs involved in lifting work shall be at the responsible person`s command, and
cooperate with each other.
12) Start lifting and positioning the equipment steady with low speed. During lifting, crane
shall keep being steady and with a constant speed. Prohibit speeding up the crane suddenly.
13) Crane driver and person in charge of lifting work shall carry out the compliance inspection
for crane situation, ground bearing capacity and sling preparation, etc. before lifting.
14) Before lifting, staffs involved in lifting work shall be familiar with the parameters
(including weight, gravity center, outline dimension, and precision) of equipment to be

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 Lifting Plan of One Free Water Separator Installation

hoisted, and adopt necessary technical measures.

15) During lifting, set out warning line and obvious warning sign within construction area.
Only authorized person can get in.
16) Standing under the equipment being hoisted or the crane beam is prohibited. Do not stay
close to stressed slings.
17) If wind speed is more than level 5, or there is heavy rain or fog, do not perform any lifting
work.
18) Fix the slings firmly. Protect corner and angle of the equipment to be hoisted with soft
material, which is to prevent slings from being damaged.
19) During lifting, use hemp rope to control direction and swing of the equipment being hoisted.
20) During crane operated, all staffs shall obey the command and cooperate with each other.
Crane driver shall comply with the Crane Operation Regulations. Signal from the
commander shall be accurate and correct.
21) For lifting work, gesture is used as the main command way, whistle is the backup
communication way.
8. Appendixes
Appendix 1 – Force calculation of slings
Appendix 2 – Vertical view for lifting
Appendix 3 – List of main tools and machines
Appendix 4 – Performance Sheet of Crane 100 T
Appendix 5 – Construction Organization Chart

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 Lifting Plan of One Free Water Separator Installation

8.1 Appendix 1： Force Calculation

1) Calculate lifting load:

Qi=(Q1+ Q2) *K1

Q1 –weight of equipment and accessory, 12 T

Q2 – net weight of equipment, 1 T

k1 – dynamic coefficient, 1.1

Qj=(Q1+ Q2)*K1=(12T+1T)*1.1=14.3T

2) Take Free Water separator body for instance. See above figure for sling connection.

Calculate lifting load:

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 Lifting Plan of One Free Water Separator Installation

Qj=K1*Q*g

k1 – dynamic coefficient, 1.1

Q – net weight of equipment, 12000kg

g – gravitational acceleration constant, 10 m/s^2

Qj=K1*Q=1.1*12000*10=132000（N）

The lifting belts is 20T,the shackle is 25T and the wire rope is 11.4T, both more than 5.436T,
and meets requirement

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 Lifting Plan One Free Water Separator Installation

8.2 Appendix 2：Vertical View for Lifting

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 Lifting Plan One Free Water Separator Installation

8.3 Appendix 3：List of Main Tools and Machines

No. Name Specification Unit Quantity Remarks

1 100 T mobile crane Set 1 Two shifts

2 25T mobile crane Set

3 Low bed Trailer 30T Set 1 Two shifts
4 Truck 10T Set 1
5 Sling 20T*10M Pc. 2
6 Wire rope φ35*8M Pc. 4
7 Sling 5T*6M Pc. 4
8 Bow shackle 25t Pc. 4
9 Bow shackle 35T Pc. 2
10 Bow shackle 6.5t Pc. 4
11 Chain block 5t×3m Pc. 4
12 Chain block 3×3m Pc. 2
13 Safety harness With Five points Pc. 4
14 Whistle Pc. 5
15 Anti-swing rope 20M Pc. 2

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8.4 Appendix 4： Capacity Sheet of Crane 100 T

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8.5 Appendix 5： Construction Organization Chart

现场负责人
Construction Commander

质量负责人 机械负责人 安全负责人

Quality Responsible Person Mechanical Responsible Person Safety Responsible Person

吊装指挥
Lifting Commander

吊车司机 起重工 钳工
Crane Driver Riggers Fitters

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