Refinery Rigging

(Field Guide)
 TABLE OF CONTENTS

1 Purpose 2

2 Capacity Reductions 3

3 Rigging Best Practices 15

4 Capacity Charts 19

5 Weight Calculations 22

6 Inspection Criteria 28

7 Signalperson 33

8 Broderson Cranes 37

9 Site Safety 47

10 Knots 53

11 Glossary and References 55

1
 Purpose

This book is meant as a quick reference field guide and

does not replace the requirement for qualified Riggers to
be familiar with Standards, Regulations and Policies
listed in the References.

The material presented is consistent with standards for

Basic Rigging and Flex Rigging training.

Advanced Rigging and Mobile Crane certification

concepts are outside the scope of this book.

Core Competencies of a Basic/Flex Rigger (at a

minimum):
- Calculate capacity reductions to WLLs of slings,
hitches, hardware, rigging configurations.
- Calculate basic load weight, center of gravity, sling
tension.
- Inspect slings, hardware and rigging gear.
- Select and attach rigging gear appropriate to the lift.
- Signalperson qualified.
- Understand Gross/Net Load/Capacity as it regards
crane operations.
- Identify and mitigate crush/pinch points and other site
safety hazards.

2
Capacity Reductions: Definitions

Working Load Limit WLL is the Rated Capacity of

rigging gear based on the ideal rigging situation and
configuration. It is calculated in straight line pulls, never
side loading.

Example: the tag on a web sling will show the WLL

for a basket hitch, but that will only be true for the
ideal configuration, 90.

Reduced WLL is when the WLL must be Reduced

because of the rigging situation and configuration.

Example: a basket hitch at a 30 configuration will

have its WLL reduced by half. (see page 5). When
you decrease the angle the WLL must be adjusted to
a reduced level.

NOTE: Rigging equipment does not operate at rated

capacity safety factor indefinitely. A variety of things can
degrade it: corrosion, stress, UV sunlight, damage, etc.

3
 Capacity Reductions: Basket or 2-leg Vertical Hitch

As Sling Angle is lowered:

1. Load Capacity (WLL) decreases.

2. Sling Tension increases.

4
Capacity Reductions: Basket or 2-leg Vertical Hitch

Calculate Sling Tension. (L x LAF) / 2 = Sling Tension.

Example (2 legs):
1. Determine sling angles. (45)
2. Select corresponding Load Angle Factor. (1.414)
3. Multiply Load weight by Load Angle Factor to get
total load on sling legs.
(2000 lbs x 1.414 = 2828 lbs)
4. Divide total load by number of sling legs.
(2828 lbs 2 = 1414 lbs per sling leg)
5. Select slings from the single vertical leg column
within the sling capacity table.

5
 Capacity Reductions: D/d Ratio - Wire Rope

D/d Ratio, as it applies to wire rope, is the Diameter of the

Load or Hardware divided by the diameter of the wire rope.
A fully rated wire rope Basket Hitch must have 90 sling legs,
a D/d Ratio of at least 25:1, an even wrap.

D/d Ratios smaller than 25:1 will reduce the WLL.

For example: If the shackle or object has

2 times the diameter of the wire rope sling
(D/d 2:1) the basket sling capacity will be
65% of WLL. So if a Basket Hitch WLL is
1000 lbs, a 2:1 D/d ratio will reduce it to a
650 lb Reduced WLL.
WLL x .65 = Reduced WLL
A D/d ratio of 1:1 will cut WLL in half.

6
Capacity Reductions: D/d Ratio (sling eyes)

The eyes of wire rope Eye and Eye slings have the
advantage of being like mini-baskets in that the
capacities are double that of the body.
eye body eye

So if the body is rated at 1000 lbs. in a vertical

hitch, the eyes will have a 2000 lb capacity.

D must not be smaller than d.

However, if a shackle of the same diameter is

used, D/d ratio of 1:1 is in effect which reduces
the eye capacity in half. The eye is reduced to
1000 lbs. to equal the body WLL.
(This does not apply to thimbled eyes.)

D must not be bigger than half the Eye Length.

If the Diameter of the hardware in a wire rope sling

eye is too big, it spreads the eye into wide angles
against the swaging which reduces WLL in the
same manner as basket hitch angle reductions.

(For web sling eyes, D must not be bigger than

one third the Eye Length.)

7
Capacity Reductions: D/d Ratio-Chain Slings

A Chain Sling D/d ratio must be 6:1 and above to equal

the WLL of a Basket Hitch listed on the sling tag.

8
 Capacity Reductions: Chain Slings

Do not use Synthetic Slings in temperatures above 180.

9
 Capacity Reductions: Choker Hitch

When a Choker Hitch Angle is less than 120, the

choker capacity (WLL) must be adjusted.

10
Capacity Reductions: Choker Hitch
Examples: WLL on the Tag for this sling in a Choker hitch
is 7.2 tons.

Determine Reduced WLL using the

Reduction Factor from the Table.

Example one, 120

WLL x RF = Reduced WLL
7.2 x 1.00 = 7.2 tons.
Full choker capacity.

Example two, 30
WLL x RF = Reduced WLL
7.2 x .50 = 3.6 tons.
Reduced choker capacity by half.

Tip: resist the urge to pound down a

choke to grab the load. Double
wrap the choke instead.
11
 Capacity Reductions: Shackles
Shackles symmetrically loaded with an included angle of
120 can be used to the full WLL.
Do not exceed 120 included angle loading.

However, Shackles that are single side loaded will have

a Reduced WLL (see next page).

Multiply Rated Capacity (WLL) by Reduction Factor to

get actual Reduced Working Load Limit.

WLL x RF = Reduced WLL

Examples a Shackle rated 1000 pounds can lift:

1000 x 1.0 = 1000 pounds in-line.
1000 x 0.7 = 700 pounds at 45.
1000 x 0.5 = 500 pounds at 90 (half).

12
Capacity Reductions: Shackles

For Screw-Pin and Bolt-type shackles only. Do not

side load Round-Pin shackles.
13
 Capacity Reductions: Eyebolts

Angle pull in the plane of the eye only.

Use shims to line up eyebolt.

14
Rigging Best Practices:

Included Angle limitations: when attaching multiple slings

to a hook:

If greater than 90 sling attachment is required, use a

shackle, pear link or master link out to 120.

15
 Rigging Best Practices:

Wrong Hook Loading methods.

Attaching to a Hook.

Attaching to Eyebolts.

16
Rigging Best Practices:

Attaching to Shackles, gather slings in the bow.

Attaching to Hoist Rings, ensure free rotation.

Chain sling no-nos.

17
 Rigging Best Practices:

Folding, Bunching or Pinching of synthetic slings will reduce

the WLL and should be avoided.

18
 Capacity Chart: Roundsling (Lift-It)

Minimum Connection Diameter, as the above table

references, is the minimum diameter a connection device
(shackle, ring, hook) must have to avoid WLL reduction.

Minimum Edge Radii - unprotected

roundslings on corner edges require
a minimum radius rounded edge to
avoid too much point stress. This
can vary from 3/16th to 7/8th inch
depending on WLL.
Use Softeners and Padding to best
avoid corner stress.

19
 Capacity Chart: Slings

1.0 .75

20
Capacity Chart: Hardware

21
 Weight Calculations: Flange Weight Table

22
Weight Calculations: Flange Weight Table

23
 Weight Calculations: Pipe Weight Table

24
Weight Calculations: Material Weight Tables

25
 Weight Calculations: Formulas

Circumference of a Circle = x D. L = Length

Area of a Triangle = (L x W) 2. W = Width
Area of a Square or Rectangle = L x W. H = Height
r = Radius

Area of a Circle = r.
D = Diameter

Volume of a Cube = L x W x H.
= 3.1416
Volume of a Cylinder = r x L 1 gal = .134 cf
(pipe, tower, tank). 1 cf = 7.48 gal
1 in = .0833 ft
Pythagorean Theorem: a + b = c. 1 si = .00694 sf
1 sf = 144 si
So, a = c - b
b= c - a
c= a + b

26
Weight Calculations: Example

Calculate the weight of a Tank using the

Tables & Formulas.
Diameter 10 ft, height 15 feet, steel in thick.

1. Calculate the Area and Weight of the top

and bottom.
Top weight = Area of a Circle x the load
weight of Steel per square foot.

= x r x r x Steel weight
= 3.1416 x 5ft x 5ft x 20 lbs/sf = 1,571 lbs.
2. Bottom = same as Top = 1,571 lbs.

3. Calculate the Area and Weight of

the Body using Circumference to
unravel the cylinder into a steel sheet.
Body weight = the circumference
of the cylinder x the height x the
load weight of Steel per square
foot.
= x D x H x Steel weight
= 3.1416 x 10ft x 15ft x 20 lbs/sf = 9,425 lbs.

4. Total weight = 1,571 lbs. + 1,571 lbs. + 9,425 lbs.

= 12,567 lbs.

27
 Inspection: Web Sling

28
Inspection: Round Sling

29
 Inspection: Wire Rope Sling

3/6 RULE: Three broken wires in one strand in one rope

lay, or Six randomly distributed broken wires in one rope
lay, where a rope lay is the length along the rope in which
one strand makes a complete revolution around the rope.

Lay Length

30
Inspection: Chain slings and hardware

31
 Inspection: slings and hardware continued

All rigging gear requires some form of identification with

rated capacity (WLL) legible.
Polyester and nylon slings shall not be used in contact
with an object or at temperatures in excess of 180F.

Hooks shall be removed from service if:

wear exceeds 10% of original dimension.
throat opening of 5%.
Any bend or twist.
Self-locking hook doesnt lock.

Annual Inspection Color Coding

5 year rotation
2015 White
2016 Yellow
2017 Red
2018 Green
2019 Orange

32
Signalperson: Voice Signals

Conducting a Voice Signal:

Maintain constant communication with the Operator once a

lift move has begun:

- Hold down the microphone key.

- Repeat the function command, talking it through.
This reassures the Operator the move is proceeding
as planned.
- Un-key the microphone at the end of the move.
- Repeat for any follow-on moves.

If the Operator senses a problem, they will stop the move.

All signals shall be given from Operators perspective.

3 elements of voice signals

1. Function (hoist, boom, etc), Direction
2. Distance and/or speed
3. Function, stop command
Example: swing right 50 ft, 25 ft, 15 ft, 10 ft, 5 ft, swing stop

Only one signalperson at a time, except when STOP or

Emergency STOP are given for safety reasons.

Audible Travel Signals:

STOP: one short audible signal
GO AHEAD: two short audible signals
BACK UP: three short audible signals
33
 Signalperson: Hand Signals (mobile crane)

34
Signalperson: Hand Signals (mobile crane)

35
 Signalperson: Hand Signals (mobile & bridge crane)

Bridge and
Gantry
Crane
Signals.

36
Broderson: Load Chart (7.45 ton)

IC-80-1D: Equipment numbers 7016 & 7045.

D model has a boom extension and All-Wheel steer.
IC-80-1B: Equipment number 2858.
B model has no boom extension and is Rear-Wheel steer.

Max boom is 20 feet, the Extension increases to 30 feet.

Load chart capacities are all Gross Capacities.

IC-80-1D and 1B
37
 Broderson: Load Chart (7.45 ton)

It is a Critical Lift if actual Gross Load exceeds 75% of

charted capacity.

- Example: If the Gross Load (load + rigging gear +

hook&ball) = 4000 lbs., can you pick this up at 16 feet
on outriggers, with extension stowed, without it being a
critical lift?
- No. (4450 lbs. x .75 = 3337 lbs.)
- 4000 lbs > 3337 lbs so it is a critical lift, move to 14 feet.

IC-80-1D
38
Broderson: Load Chart (7.45 ton)

- Example: If the Gross Load (load + rigging gear +

hook&ball) = 10000 lbs., can you pick this up at 6 feet
on outriggers, with extension stowed,single part of line,
without it being a critical lift?
- No. Single part of line is limited to 9000 lbs.
(9000 lbs. x .75 = 6750 lbs.)
- 6750 lbs. Is the max you can lift without it being a
critical lift. Install 2-part line block.

IC-80-1B
39
 Broderson: Load Chart (7.45 ton)

Note: for accurate Hydraulic Oil level indication during

pre-check, ensure boom and outriggers are fully
retracted.

IC-80-1D and 1B
40
Broderson: Load Chart Terminology
Gross Capacity = Net Capacity + deductions. These are
the numbers on the Load Chart.
Deductions = headache ball + hook + rigging gear, etc.

Net Capacity = Gross Capacity - deductions. This is the

maximum Net Load for the crane configuration.
Gross Load = Net Load + Deductions. Use this
number when checking the Load Chart. It must never
exceed Gross Capacity for the radius and crane
configuration.
Deductions = headache ball + hook + rigging gear, etc.

Net Load = Gross Load - deductions. Actual weight of

item lifted.
Load Radius - Horizontal distance from center of
rotation to CoG of the load.
Ground Bearing Pressure - to avoid soil cave-in, the
pressure of the outrigger mats/cribbing on the ground
must be determined and not exceed:
1. Dirt or Gravel - 1000 psf
2, Asphalt - 2000 psf
3. Concrete - 3000 psf
Determine if the mat size is sufficient:
Area = 0.65 x (Crane weight + Load weight)
max pressure for soil type
Mat length will be the square root of the result.
41
 Broderson: Load Chart (4 ton)

42
Broderson: Load Chart (4 ton)

43
Broderson: Load Chart Terminology

If actual radius falls between the chart listings,

use next longer radius, never split the difference,
to determine the Gross Load limitation.

17 feet

If calculated Gross Load falls between the chart listings,

use next shorter radius, never split the difference,
to determine the Load Radius limitation.

4200 lbs

44
Broderson: Standard Lift Plan Checklist

Identify Load size, shape, weight, and center of gravity.

Select and inspect the proper rigging equipment and
the method for connecting and disconnecting the load.

Identify the lifting radii at the pick and set locations.

Determine head room, hoist height, travel path.
Select correct size crane for the load to be lifted.
Job site conditions, examples; obstructions, ground
conditions, crane access, SIMOPS, nearby equipment
(e.g. live process equipment, overhead power lines).
Pinch points and crush hazards identified and marked.
Environmental conditions: wind, temp, visibility,
weather.
Establish roles and responsibilities of the work crew.
Communication method agreed to by the Crane
Operator, Rigger, and Signalperson (i.e. radio, hand
signals, etc.).

A contingency plan for emergencies related or

unrelated to the lifting operation.

Lift area (fall zone) is clear of non-essential personnel,

and is properly barricaded.

45
 Broderson: HUSS Filter

Regeneration Procedure
1. The vehicle should stand level.
2. Switch off the motor.
3. Ignition: ON, do not start engine. Voltage is supplied
to the Control Unit.
4. Press M and hold for 5 seconds. The display will
countdown 5 seconds, then regeneration will begin.
You can interrupt regeneration by turning OFF the
ignition on smaller vehicles, or by pressing the F key.
5. Allow several minutes to finish. Filter casing will be
very hot.

46
Site Safety

Pinch-points and Crush Hazard Areas

- Identify and mark pinch-points and crush hazard

areas.

- Before an employee enters the hazard area, out of

view of the operator, the operator must be informed.

- The operator shall not rotate the superstructure until

the operator is informed that the employee is in a safe
position.

Crane Operators shall observe, or have a Signalperson

observe, each outrigger during extension, setting, and
retraction.

47
 Site Safety

Never walk or work under a suspended load.

Never ride a load.

Avoid swinging loads over other people.

Use tag lines for positioning and controlling loads.

Spotters are required for all cranes over 15 tons traveling

LAR roadways.

Wind speeds
> 20 mph - LTA approval required to continue lift.
> 30 mph - stop Lifts.

Line of Fire: identify rigging line of fire.

Examples: slings and hoists under tension, wire rope
under bundle pulling stress.
Avoid standing near or in-line with stressed rigging and
cables to avoid snap-back if it breaks.

48
Site Safety: Hoists

Chain hoists are intended for use in a vertical or near

vertical position only.
Come-alongs can be used vertically, horizontally or on an
angle. DO NOT use cheater bars.

Load rating of the supporting structure or anchoring

method must be equal to or greater than the hoist.
Hoisting from non-process equipment is preferred.

If a process line is to be used as an anchor, select the

appropriate pipe size for the load from the Table. Pipe
condition must also be considered and risk assessed.

49
Site Safety: Power Lines

Maintain 20 feet clearance from power lines.

To preventing encroachment / electrocution:

- Use non-conductive tag-lines.
- Erect elevated warning lines, signs, barricades, flags
to mark minimum approach distance to the
Prohibited Zone.
- Use a Dedicated Spotter:

Dedicated Spotter: a qualified Signalperson whose sole

responsibility is to:
- watch the separation between the power line and the
equipment,
- watch the separation between the power line and the
load line and load (including rigging and lifting
accessories),
- ensure through communication with the operator that
the applicable minimum approach distance is not
breached.

50
Site Safety: Power Lines

Electrocution:

Can result from contacting the ground and any part of

the crane, hoist wire or load simultaneously.
Can result from stepping across ground voltage
differential which occurs as the voltage passes
through ground resistance the further it travels.
The distance of a mere stride can be enough voltage
difference to electrocute you.

Procedure: Ground Crew

- Do not touch crane or hoist line or load.
- Maintain balance and hop with feet together or shuffle
away from the affected area.
51
Site Safety: Power Lines

Procedure: Crane Operator

- Stay in the crane.
- Attempt to move crane away from electrical hazard.
- If it becomes necessary to abandon the crane, DO
NOT step down from the crane. Jump away with feet
together.
- Maintain balance and hop with feet together or shuffle
away from the affected area.

52
Knots

Bowline

Clove
Hitch

53
 Knots

Round Turn & 2 Half Hitches

Timber Hitch & Half Hitch

54
Glossary

CoG - Center of Gravity.

Critical Lift - Lifts exceeding 75% of the cranes capacity as
configured, multiple crane lift, lifting personnel, lifts near power
lines, tilting, high-risk lifts.
Dedicated spotter (power lines) - is a qualified Signalperson
with the sole responsibility to ensure no portion of the crane or
load encroaches upon the prohibited zone.
D/d Ratio - the ratio of the diameter around which a wire rope
sling is bent, divided by the body diameter of the wire rope sling.
Gross Capacity & Gross Load - see page 37.
Lift Director - The qualified Rigger that is directly in charge of
the work crew performing the task/lift.
LTA - Lifting Technical Authority - overall accountability for
lifts. Provides technical advice and assurance, ensuring
procedures are followed.
Minimum Connection Diameter - is the minimum diameter a
connection device (shackle, ring, hook) must have to avoid WLL
reduction on roundslings.
Minimum Edge Radii - unprotected roundslings on corner
edges require a minimum radius rounded edge to avoid too
much point stress. This can vary from 3/16th to 7/8th inch
depending on WLL.
Net Capacity & Net Load - see page 37.
Prohibited Zone - the area immediately surrounding an
Electrical Hazard in which no lifting operations or other work is
allowed. For lifting operations at LAR, the minimum radius of the
Prohibited Zone is 20 feet.
Working Load Limit WLL is the rated capacity of Rigging
gear based on the ideal rigging situation and configuration. It is
calculated in straight line pulls, never side loading.
Reduced Working Load Limit RWLL is when the WLL must
be Reduced because of the rigging situation and configuration.
55
References: Standards, Regulations, Policies

ASME B30.5 Mobile Cranes

ASME B30.9 Slings
ASME B30.10 Hooks
ASME B30.26 Rigging Hardware
CAL/OSHA CSO Construction (1610-1619)
CAL/OSHA GISO General Industry (4884-5049)
HSS-602 Mobile Crane Safety
HSS-604 Rigging and Hoisting
MNT-RIG-023 Inspection & Maintenance Requirements
for Rigging and Hoisting Equipment

References: General

IPTs Crane and Rigging Handbook, Ronald G. Garby

Journeyman Riggers Reference Card, ITI
Lift-It Catalog
Mobile Cranes, James Headley
Rigging Manual, CSAO

56
57
58
59
60
(8/20/2015)