How to Plan a Critical Lift for Oil and Gas in Saudi Arabia
A critical lift plan turns a dangerous pick into a controlled, repeatable procedure. In oil and gas it is the document everyone signs before the crane moves.
Refinery columns, reactors, compressor modules and flare equipment are heavy, expensive and often lifted close to live plant. When a lift is complex or critical, the crane is only one part of a system that includes engineering, permits, ground preparation, communication and a stop-work culture. This guide explains how a critical lift plan is built for oil and gas work in Saudi Arabia, using the lift categories in ISO 12480-1 and two published examples: an Aramco flare tip removal and a refinery turnaround with 109 lifts.
Lift categories: routine, complex, critical
ISO 12480-1 sets out lift categories as routine, complex and critical, together with the appointed person role and the competent team structure. The exact thresholds that make a lift critical are set by the client, so check the client's procedures. Typical triggers are heavy loads close to crane capacity, long radius, lifts over live equipment, personnel lifting, restricted space and difficult ground. If you are unsure, treat the lift as critical and plan accordingly.
What a critical lift plan contains
| Section | Content |
|---|---|
| Load data | Weight, centre of gravity, lifting points, rigging weight and the lift path. |
| Crane data | Model, boom and jib configuration, counterweight, radius and the load chart percentage used. |
| Ground and set-up | Ground bearing, levelling, outrigger mats, access and swing clearance. |
| Rigging | Slings, shackles, spreader beams, sling angles and certificates. |
| People and communication | Named appointed person, operator, riggers, signaller, radio channel and stop-work authority. |
| Environment and permits | Wind limit, lifting window, hazardous area, work permit and lift permit. |
A published Aramco example
A published account of a flare tip removal at Aramco's Khursaniyah Gas Plant used a Terex AC 350 all-terrain crane of 350 tonnes with a 56 metre main boom and 37.5 metre fixed jib, a 32 tonne counterweight and a 22 metre working radius to lift a flare tip of about 5 tonnes. Personnel were lifted in a crane-suspended platform, so crane capacity was derated to 50 percent and wind speed was limited to 25 km/h. A work permit, a critical lift plan form and a personnel platform permit were all approved by the relevant authorities. Ground bearing and levelling were inspected by a certified rigger and a heavy lift engineer, wind was monitored continuously to pick a window, radios linked operator and rigger, and taglines controlled the platform.
A turnaround at scale
A published account of an Aramco refinery upgrade in Riyadh describes 109 lifts, including eight hydrocracker reactors of 450 tonnes each, inside a 40-day window. Route surveys and lifting studies started long before the shutdown. The lesson is simple: involve the lifting contractor early, run separate equipment spreads for each work area and plan assembly sequence in limited space.
- Start the lift study as soon as the equipment weights and positions are known.
- Agree wind limits and a stop-work authority before the day, not on it.
- Prepare documents early: inspection certificates, load charts, operator approvals and gate passes.
Common reasons critical lifts are delayed
Most delays are paperwork and ground, not the crane. The lift plan arrives late, the rigging certificate has expired, the wind rises above the limit on the planned morning, or the ground at the set-up position was never checked. Each of these is avoidable. Agree who owns each document, set a date for the lift plan review a week before the lift and keep a spare window in the programme. In summer, remember that the midday outdoor work ban restricts the working day, so a long lift may need to start at first light.
A useful habit is a short pre-lift meeting on the day. The appointed person walks the team through the plan, the stop-work triggers, the exclusion zone and the radio channel, and everyone confirms their role. It takes ten minutes and prevents most misunderstandings once the load leaves the ground.
Who approves a critical lift plan?
The client or main contractor's procedure decides, usually involving the appointed person, a lifting engineer and the site HSE authority. Ask for the approval route when you request a quote.
Can you prepare the lift plan for us?
Responsibility for the lift plan is agreed in the contract. Tell us whether you or we prepare it, and whether a third-party lift engineer is required.
Related services and guides
- Mobile and rough-terrain crane rental
- Refinery and petrochemical equipment rental
- Oil and gas equipment rental
- Equipment rental in Jubail
- What is a contract lift?
Sources: KHL, How did Saudi Aramco tackle a flare tip removal project? (31 May 2022) · Mammoet, turnaround at Saudi Aramco's Riyadh refinery · HOE, crane operator licensing in Saudi Arabia · Kanoo Machinery, SASO and Aramco lifting equipment standards
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Key points: critical lift
Need help with critical lift? Ariane Ventures advises on critical lift for projects across Saudi Arabia, from our Dammam yard to oil and gas fields and industrial cities. We are a registered Saudi Aramco vendor, and our team can review your critical lift requirements and send a quotation, usually within one working day.