e 29 gp 002 lifting and hoisting planning & recording

This printed copy is only valid for 17/04/2018

RICHARDS BAY MINERALS RICHARDS BAY MINERALS

RBM GENERAL PROCEDURE

Effective Date: 26 June 2017

APPLICABLE TO

All Divisions

PROCEDURE NO

E 29 GP 002

REVISION NO

5

PAGE

1 of 11

LIFTING AND HOISTING PLANNING & RECORDING

Compiled by: Manager RMM Smelting and Processing

1. PURPOSE

This procedure applies to any task where a risk assessment highlights potential dangers to personnel or the company property when using a crane and rigging equipment. To ensure that all rigging conducted on site is done safely and without danger to property and personnel.

2. STANDARDS RBM recognises that lifting operations are inherently hazardous and thus require special attention to prevent injury to personnel and damage to property. Each plant within RBM must identify its lifting operations and classify them as either critical lifts or non-critical lifts. The lifts must be classified using the guideline outlined in the flowchart for evaluating lifts in Appendix 1.

2.1 PLANNING

2.1.1 General Requirements

A safe working environment must be provided by performing a Risk Assessment followed by a lift plan for all critical and Non-critical lifts. The following general requirements apply to all crane and rigging practices:

a) A Pre-job Risk Assessment shall be performed and the outcomes evaluated in accordance with Appendix 1 & 2 of this procedure - prior to performing any task utilizing a crane or lifting equipment

b) A detailed critical lift procedure/plan (Appendix 3) with a pre-job risk assessment (Appendix2) will be followed when:

Multiple cranes are required to perform the lift

The lifting load mass (85% of the load) is close to the rated capacity of the crane

The total weight on the hook exceeds 20,000 kilograms

Personnel exposure to suspended loads or to crane operations

Lifting loads over power lines

Lifting over operating facilities in areas that could pose a risk to personnel or company property

Lifting personnel using a man basket

When indicated as a critical lift by this procedure

c) A detailed Non-critical lift procedure/plan (Appendix 5) with a pre-job risk assessment (Appendix2) will be followed when for all lifts not meeting above criteria

E 29 GP 002 REV NO: 5 PAGE 2 OF 12


d) The plan shall include the following:

Lift Data: Equipment weight, rigging weight, total weight, height of lift, radius of lift, centre of gravity and equipment surface area

Equipment Data: Manufacture, model, size, boom length, jib length, load block, material size, lifting capacity

Rigging Data: Sling diameter, sling length, sling configuration, capacity, hook type, shackle size and capacity

Lift Computations: Boom length, radius of lift, equipment capacity, size of outrigger footplates and wind speed

Proximity to Power Lines and Process Areas: Mobile cranes working in the proximity to energized power lines must operate under a proximity permit, which must define the exclusion zones and spotter duties

Local Hazards and Controls: To include the route of the crane, ground stability, proximity of people or equipment and an agreed communications method

e) Crane Operators and all personnel associated with a critical lift must be a participant in the preparation of the lifting plan

2.1.2 Rigging Operation

a) Determination of Mass: It is important that the mass of the object to be lifted is determined prior to any work commencing. Lifting equipment and tackle to be chosen for this load only

b) Load Stability: The rigger must ensure prior to lifting that the load when lifted will not tilt. It is therefore essential that the centre of gravity of the load being lifted is determined prior to lifting tackle being attached

c) Balancing of the Load: In the event where it is not possible to use fixed length slings when attempting to balance a load, use can be made of a chain block

d) Supervision: All rigging must be carried out by a qualified person/s. Critical lifts must be carried out under the supervision of a person competent to identify all hazards related to the tasks or as otherwise directed by the 2.13.1 / 2.13.3.1 or 2.13.3.2 Appointee

e) Pre-start Checks: Crane operators must carry out pre-start checks on a daily basis or at the start of each working shift

Pre-start checklists are to be produced for individual cranes and stored in areas to allow ease of access for both operators and maintenance teams

The checklist books are to be reviewed by area operations team leaders periodically and completed books retained for a period of 3 months

Pre-start checks are to be based on the details identified in the risk assessment of all cranes. (Refer to RBM COP 70)

No crane is to be operated with an inoperable or defective safety device

Mobile cranes must have their slew pins locked in place while traveling

Slewing to test the integrity of outriggers on mobile cranes must be conducted prior to commencing lifting

f) Use of Tag Lines: Tag lines must be attached to loads that require steadying or guidance while suspended unless otherwise specified in a documented risk assessment. The load must be well secured and properly balanced in the sling or lifting device. The people on the tag lines shall have training in the safe use of tag lines



g) Communication: There must be a documented method of communication between crane operators and slinger/signalers within the critical lift plan. Acceptable methods are:

Visual hand signals when the slinger/signaller and the load are always in the clear view of the operator (In accordance with BS 7121:Part1)

Audible signalling (whistles) if the load and slinger/signaller are out of the view of the operator and the distance from the crane is not great and ambient noise does not drown out or garble signals.

Radio communication should be used where the load and the slinger/signaller are out of sight of the operator and far enough away such that audible signalling is impractical. The use of hands-free headsets for crane drivers is recommended

h) The operator shall not leave the crane controls while a load is suspended i) 2.13.1 / 2.13.3.1 or 2.13.3.2 and MHSA Chapter 2 Section 7 appointees to ensure that only

persons deemed competent i.e. has the skill and knowledge and training, to operate lifting tackle and machinery by virtue of his qualifications and training. Only suitably trained persons shall perform lifting tasks

j) The user shall satisfy himself that all lifting equipment and machinery is safe to operate prior

to use k) The engineer, supervisor or competent person in charge shall ensure that lifting equipment

and machinery is used only for the purposes for which it was designed

l) The supervisor shall ensure that access to areas where lifting operations are carried out are restricted, protected and suitable procedures are in place to ensure that persons in the vicinity are not subject to hazards

m) A competent, qualified person shall control every lift, with detailed risk assessments made for

any but the simplest of lifts

n) During abnormal wind conditions the Pre-lift assessment in Appendix 4 must be carried out.

3. REFERENCES COP 29

4. APPENDICES

The following documents are referenced by or used in these procedures, each provided on a separate page for printing purposes:

1. Flowchart for evaluating lifts

2. Pre-Job Risk Assessment for cranes and lifting

3. Critical lift plans for lifting and hoisting

4. Crane lifts during abnormal wind conditions

5. Non critical lift plan



5. REVIEW HISTORY

REV NO DESCRIPTION PAGE (S) DATE

1 General revision All 02.10.2005

2 Replaced all references to 2.13.3.2 with 2.13.1 / 2.13.3.1 or 2.13.3.2

All 29/09/2006

3 Point 2.1.1 (b)

Second bullet : Insert : 85% of the load

Fifth bullet: Replaced “There is a danger to personnel” with “Personnel exposure to suspended loads or to crane operations”

Appendix 3 – Point 8 – Signatures

More details added in brackets on “Appointed Persons acceptance of Responsibilities”.

1

10

24/05/2010

4 Item 2.1.1.(b) Removed bullet : The wind speed exceeds 32kph.

Item 2.1.2 – Rigging operation - added point n:

During abnormal wind conditions the pre lift assessment in Appendix 4 must be followed.

Appendix 2 – Job risk assessment for cranes and lifting

Changed description under Windy Conditions to read:

Performing lifts where wind conditions are at variable velocities. Follow assessment in Appendix 4 on page 1. A “Critical Lift Plan” must be performed.

Added Appendix 4 – Cranes lifts during abnormal wind conditions.

1, 2, 3 & 11

5 Item 2.1.1 Added and non-critical

Item 2.1.1b Changed Appendix1 to Appendix2

Item 2.1.1c A detailed Non-critical lift procedure/plan (Appendix 5) with a pre-job risk assessment (Appendix2) will be followed when for all lifts not meeting above criteria

Changed Approval Manager name from B Hare to S Houston-Mcmillan

Changed REQUEST FOR A VARIANCE to read Technical and Asset Management instead of Engineering’s office

Removed text from REQUIREMENTS FOR NON-CRITICAL LIFTS, BULLET 3, may require a lift plan or

checklist, or

1

1

1

5

7

77

21/06/2017



Added bullet 4, During non-critical lifts the “Non Critical Lift Plan” in Appendix 5 must be carried out

Appendix 1 – Flowchart : Added Non-critical lift plan on flowchart

Added P to read PRE

Changed page number to 11 under windy conditions

Changed Appendix 4-5 to Appendix 4

Inserted Appendix 5 Non-critical lift plan and attachment

8

9

9

12

12

APPROVAL

POSITION NAME DATE SIGN

Manager : RMM Smelting and Processing

S Houston-

Mcmillan



Appendix 1

Flowchart for Evaluating Lifts

PURPOSE:

Determining if the lift is CRITICAL or NON-CRITICAL

This flowchart covers THE handling of any mechanical device, which is capable of lifting, lowering, or otherwise moving material or personnel.

ENVIRONMENT OR LOAD:

The RBM designated 2.13.1 / 2.13.3.1 or 2.13.3.2 appointee, or a formally designated appointee is responsible for identifying and evaluating the following three areas:

HIGH COST IMPACT: Is there a risk of high monetary loss if an unplanned incident occurs during the lift? This loss includes damage to the item itself or to the surrounding environment

PRODUCTION IMPACT: Is there a risk of an adverse effect on the production schedule or project mission success if an unplanned incident occurs during the lift? Items to consider include space flight, institutional activities, base operations, and potential political impact.

SPECIAL SAFETY CONCERNS: Is there a risk to the safety, health, or well being of personnel or lifting equipment beyond normal accepted lifting risks? Is a crane of any kind being used to lift personnel? Is there any possible adverse environmental impact?

REQUIREMENTS FOR CRITICAL LIFTS:

If the answer to any one of the questions above is yes, then the lifting task is considered a critical lift. Critical lifts must meet the requirements of references specified in Section 6 of this procedure. The following summarises these requirements:

PROCESS AND PROCEDURES:

A lift plan, checklist, and hazard analysis must be developed. Assess the procedures and hardware used in the lift. Make sure that personnel have received adequate operational

training in using that particular device, equipment, and hardware and that Lift Certifications are current. Procedure E29GP001 contains a sample lift plan and checklist.

MATERIAL HANDLING DEVICE AND EQUIPMENT:

Answer the following questions on the mechanical device and equipment used to lift, lower, or otherwise move material or personnel: Is the device and equipment used in the manner for which it was designed? Is the

planned lifting task using the equipment in the same manner intended by the manufacturer? Are the parameters in the lift plan within the design parameters of the device and equipment?

Does the device and equipment meet minimum design criteria as defined? Hardware not built to design criteria must be analysed to make sure it meets or exceeds the requirements.



REQUEST FOR A VARIANCE:

If the answer to any of the above “MATERIAL HANDLING DEVICE AND EQUIPMENT” questions is no, then a request for variance must be obtained from the General Manager Technical and Asset Management. If the variance isn’t approved, then an alternative method must be obtained to perform the lift.

VERIFICATION AND VALIDATION:

The material handling device and equipment must have the required maintenance, testing, inspection, and certification as defined.

TRAINING AND CERTIFICATION:

The personnel involved with the lift must have both the required operational training and certification defined in cop 29. This includes operators, riggers, or anyone within the designated safety zone of the lift. Critical-lift operators must be recertified yearly. Procedures, lift plans, and checklists must all have written approval.

EXECUTION:

All tasks detailed above must be complete before preparing for or performing the lift.

DESIGNATED PERSON IN CHARGE OF LIFT:

The responsible organisation must appoint a person. Such person must monitor critical-lift operations to make sure they follow RBM COP 29.

PERFORM PRELIFT BRIEFING AND LIFTING OPERATION PER THE LIFT PLAN:

A pre-lift briefing must be held to familiarize all personnel with the specific details of the lift plan. The lift, as per lift plan may then commence.

REQUIREMENTS FOR NON-CRITICAL LIFTS:

If the answers to all questions under “ENVIRONMENT OR LOAD” are no, then the lifting task is considered a non-critical lift. All non-critical lifts must follow the requirements of this procedure:

The procedures and hardware used in the lift must be assessed

Make sure that personnel have received adequate operational training in the use of that particular device or equipment and that Lift Certifications are current

The 2.13.1 / 2.13.3.1 or 2.13.3.2 appointee may impose additional restrictions or criteria not covered by this flow chart before doing certain non-critical lifts. This will be assessed on a case-by-case basis

During non-critical lifts the “Non Critical Lift Plan” in Appendix 5 must be carried out

E29 GP 002 REV NO: 5 PAGE 8 OF 12


APPENDIX 1 (Continued)

Flowchart for Evaluating Lifts

Lifting Task Environment Process & Procedures Device & Equipment

Or Load

Production

Impact?

Special Safety Concerns?

Approved

Variance Request Approved

Non-critical lift

Pre-Use Checklist Risk Assessment Non-critical lift plan

Request Variance

Request Variance

Verification and Validation Execution

Critical Lift

Any Mechanical means of handling material

High cost

Impact?

Being used in the manner for which

designed?

- Personnel Certification - Operational Training - Lift Plan - Checklist - Hazard Analysis - Formal Risk Assessment

Meet minimum design criteria?

Person designated “in charge of the lift”

Perform pre-lift briefing of lifting operation as per the lift plan.

Yes

Yes

No

No

Yes

No

No

No No

Yes Yes

Yes

Execution of lift

Yes

Execution of lift

No

Investigate new method to execute the lift



APPENDIX 2 PRE JOB RISK ASSESSMENT FOR CRANES AND LIFTING

Plant: Date:

Complete Description of Equipment:

Work Order/Project Number: Assessed by:

Possible Hazards Caused by Permit Space Design

No Yes Hazard Description/Next Step

Danger to Personnel

Any condition that makes it dangerous to personnel when utilizing a crane or rigging equipment. Exposure to suspended loads or to crane operations.

Lifts Over or Near Power Lines

Any condition when using a crane to hoist materials over or near power lines or when working in the area of power lines

Multiple Crane Lifts A lift requiring the use of multiple cranes

Lifts Over Operating Facilities

Performing crane lifts over facilities where there are personnel inside and it could create a safety hazard to personnel

Mass of load very close to the

Rated Load Capacity of the Crane

Lifting materials, with mass which is close to the (exceeding 85%) rated load capacity of the crane.

Personnel Man Basket Lifts Lifts Requiring the use of a man basket to hoist personnel

Windy Conditions

Performing lifts where wind conditions are at variable velocities. Follow assessment in Appendix 4 on page 11. A “Critical Lift Plan” must be performed.

Poor Illumination Performing Lifts where visibility is low

Unstable Ground or Possible

Voids Under Concrete

The possibility of loose soils eroding or concrete failing due to voids during a lift. Do not perform a lift where these conditions exist.

Unknown Load Capacity Lifting loads with unknown weight capacities.

Swing Radius

Obstructions, which could create a hazard when swinging the load or the crane boom.

Falling Objects Objects within or outside the space that may strike the crane or operating personnel.

If the entire list above is marked NO then the Risk Assessment conforms to the Rio Tinto Safety Standard C6 definition

for a Non Critical Lift Plan. A NO answer to all means there should be no inherent hazards associated with performing

the work with a crane and lifting equipment.

If any of the above is marked YES then a Documented Critical Lift Plan (Appendix 3) with a New Risk Assessment

(Appendix 2) must be used.

NOTE: If any configuration changes, then a re-assessment must be performed.



APPENDIX 3

CRITICAL LIFT PLAN FOR LIFTING AND HOISTING

1.0 Load Details

Max Weight Max Radius

Load Size C of G

Height of Lift Other

2.0 Crane Details

Capacity & Type Boom Length

Outrigger Load Counterweight

Outrigger Spread Weight of crane

3.0 Site Conditions

Access for Crane

Access for Transport

Lifting position

4.0 Hazards

Overhead power lines Crane placement (jetty)

Overhead obstacles Road closure required

Underground services Hazardous materials

Excavations Weather

Confined work area Other vehicles movement

5.0 Crane Accessories

Slings (wire) Shackles

Slings (chain) Beams

Slings (web) Mats

Other:

6.0 Method of Communication

Communication between the crane driver and the slinger/signaler will be achieved by:-

7.0 Method Statement

METHOD STATEMENT

STEP ACTION

1. Crane to arrive at lift location at _____________ on ____________

2.

3.

4.

5.

6.

7.

8.

9.



8.0 Signatures

Appointed Persons Acceptance of Responsibilities (2.13.3.1 Appointee – Plant Engineer)

I confirm that I have planned this lift in accordance with necessary legislation and accept responsibility as The Appointed Person

Signed: Date:

Crane Operators Acceptance of Responsibilities

I confirm that I have been briefed in the contents of this document and accept the duty of ensuring the lift is carried out to the agreed procedure

Signed: Date:

Slinger/Banksman Acceptance of Responsibilities (Rigger)


Signed: Date:

Crane Supervisor Acceptance of Responsibilities (2.9.2 Appointed Supervisor)


Signed: Date:

9.0 Sketches

Plan view: Scale:

Elevation: Scale:



Appendix 4 Crane lifts during abnormal wind conditions

CRANE OPERATIONS IN WINDY CONDITIONS.PDF

Appendix 5

Non Critical lift plan

Adobe Acrobat

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e 29 gp 002 lifting and hoisting planning & recording

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