Kennecott Utah Copper Corporation Safety and Health Standards

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1 Revisin N. 3 12/2004 Page 1 f 7 Kennectt Utah Cpper Crpratin Safety and Health Standards Standard N.: 16.4 CRANES AND HOISTS INTRODUCTION The purpse f this standard is t prvide requirements fr the peratin, inspectin, and maintenance f cranes and hists. This standard applies t all cranes including vehiclemunted cranes, equipment used as cranes, hists, lifting and rigging equipment REQUIREMENTS A register f cranes, hists, rigging attachments and lifting slings must be established There must be dcumented prcedures that require: All rigging cnnectins t be checked and crrect prir t cmmencing a lift. Checks that the lad being lifted is within the rated capacity f the crane and lifting attachments and is als within the limits set ut in the lift plan. Checks f all safety devices r verlad limiters t ensure they are nt verridden r disabled Each facility must develp a register f critical lifts and a dcumented plan fr each critical lift t address the assciated hazards. Critical lifts include all multiple crane lifts; lifts ver perating facilities where this may endanger persnnel; lifts ver pwer lines; lifts invlving persnnel cages; a nn-rutine lift f 20 tns r mre, and a lift f mre 85% f the crane's ttal lad capacity. Crane peratrs and rigging crews invlved in critical lifts must have input int the lifting plan and be cnsulted prir t finalizatin f the plan. A "Planned Critical Lift Permit" (Exhibit ) must be cmpleted and apprved by the facility Maintenance Superintendent. The lift plan must include: Lift data: equipment weight, rigging weight, ttal weight, height f lift, radius f lift and equipment surface area, center f gravity. Equipment data: manufacturer, mdel, size, bm length, jib length, lad blck, material size. Rigging data: sling diameter, length, sling cnfiguratin, capacity, hk type, shackle size and capacity. Lift cmputatin: bm length, radius f lift, equipment capacity, size f utrigger ftplates, and wind speed. Prximity t pwer lines and prcess areas: mbile cranes wrking in prximity t energized pwer lines must perate under a prximity permit (Exhibit ), which must define exclusin znes and sptter duties. Lcal hazards and their cntrls: including the rute fr the crane, grund stability, prximity f peple r equipment and agreed cmmunicatin methd. References: OSHA CFR 29 Part MSHA CFR 30 Subpart M, O, and R. ANSI/ASME B30. Equipment Manufacturers' Specificatins. Ri Tint Standard C6. Cranes and Lifting Equipment Signatures Standards Cmmittee Chairman Date Vice President Human Resurces Date President, KUCC Date Kennectt Utah Cpper Crpratin. All rights reserved. The standards n the KUCC Intranet website are cnsidered the standard in effect and supersede all ther revisins.

2 Revisin N. 3 Standard N /2004 Page 2 f Lifts nt subject t a critical lift plan must be subject t a risk assessment There must be a dcumented and apprved methd fr cmmunicatin between the crane peratr and thse assisting with the lift. Hand signals shall be thse prescribed by the applicable ANSI standard fr the type f crane in use. An illustratin f the hand signals shall be psted at the jbsite/wrk area. When hand signals are used in directing the crane peratr nly ne emplyee will be designated t give the signals. Any signal nt understd by the peratr will be taken t mean STOP. A STOP signal shall be beyed n matter wh gives the signal Lad ratings must be clearly marked n each crane r hist. Labeling fr capacities, safe lifting area, and ther pertinent data shall be kept clearly legible. Any crane r hist suspected f having been verladed shall be remved frm service and lcked and tagged ut until either repaired r re-certified by qualified persnnel. A prcedure must be in place t prevent the use f lifting r rigging equipment in lifting peratins if such equipment has been used fr twing Where practicable r where the weight f a lift is uncertain, cranes shuld be fitted with a lad cell (LMI - lad mment indicatr) with the weight f the lad displayed in the visual range f the peratr. Lad-limiting devices shall be kept in gd wrking rder Cranes shuld be equipped with an anti tw-blck device r limit switch that includes audible and visual alarms All lifting hks (except fr grab and chain shrtening hks) will be fitted with the crrect manufacturer safety latch t prevent the lad frm accidentally detaching, unless therwise specified in a risk assessment. Blcks, hks, balls, r crane lads shall nt be used fr lifting r transprting persnnel Lads must nt swing ver peple r ccupied buildings and n persn shall be under a suspended lad r in a psitin where they culd be struck by a falling lad. Where there is a risk f a lad falling and striking a persn, barricading r similar cntrls t prevent access must be in place. The peratr shall nt leave the crane cntrls while a lad is suspended Overhead travelling cranes must be fitted with effective audible warning signals Tag lines must be attached t lads that require steadying r guidance while suspended. The lad must be well secured and prperly balanced in the sling r lifting device. Tag lines must be used when the pssibility exists fr the lad being lifted t shift r swing int adjacent structures r when a swinging lad may endanger peple r prperty Mbile cranes must have a rating capacity chart fixed in a psitin visible t the crane peratr r available in the crane cabin. Mbile cranes must meet mbile-equipment safety standards including hrns, back-up alarms, seat belts, etc. Operatr cntrl statins fr vehicle-munted cranes must be lcated in an area prtected frm swinging lads and frm the crane jib. Slew pins must be secured in place in mbile cranes while travelling. Slewing t test the integrity f utriggers n mbile cranes must be cnducted prir t cmmencing lifts Mbile cranes are prhibited frm perating within 10 feet f energized pwer lines (greater distances are required fr vltages abve 50kV). Signs must be installed in all mbile cranes t infrm the peratr f this requirement. Kennectt Utah Cpper Crpratin. All rights reserved. The standards n the KUCC Intranet website are cnsidered the standard in effect and supersede all ther revisins.

3 Revisin N. 3 Standard N /2004 Page 3 f 7 A "Clse Prximity Permit" (Exhibit ) shall be cmpleted befre cnducting wrk that places a mbile crane within 15 feet f a pwerline; within any fenced substatin; within any wrk area where expsed buses are present; r when mving lads ver pwerlines r substatins; MAINTENANCE and INSPECTION There must be a dcumented prcess that ensures all critical cmpnents are inspected and in place prir t a crane being cmmissined and put int service Crane peratrs must undertake a pre-peratinal safety check fr each shift the crane is used and this shuld be kept with the crane. The detail required in the pre-peratinal safety check must be based n a risk assessment fr the crane. The peratr shall reprt any malfunctin t the supervisr immediately. A crane must nt be perated with an inperable r defective safety device Any crane brught t site must have a current test certificate and a pre-use safety inspectin t ensure the crane is fit fr purpse. As a minimum, this inspectin must satisfy regulatry and manufacturer requirements fr frequency f inspectin and physical cnditin f the machine There must be a system fr the inspectin, maintenance and apprval f lifting equipment, including a prcess that verifies the equipment is able t functin t its design specificatins and the integrity f: Mechanical and electrical cmpnents. Cntrls fr each piece f lifting r rigging equipment. Crane cables and all lifting attachments. Structural cmpnents f the hist, brakes, wheels, hks, hk-blcks and rails. Integrity f lad limiting devices, safety devices, limit switches and cntrl systems required fr individual equipment e.g. independent fail-safe braking systems, a device t stp the crane such as a dead-man switch, and emergency shut-ff switch All welding prcedures and welder qualificatins used n lad-sustaining members shall be in accrdance with AWS D14.3. Mdificatins r additins are prhibited withut written apprval frm the manufacturer All cranes shall be frmally inspected n a mnthly and annual basis. The inspectins must be dcumented, and perfrmed in accrdance with manufacturer's recmmendatins and regulatry requirements. Inspectins and repairs t cranes, cables and lifting equipment must cmply with the manufacturers specificatins and regulatry requirements as a minimum. All peratins and maintenance inspectin recrds, and cable tests recrds must be sent t the facility recrdkeeping center and retained fr ne calendar year Training Persnnel must be trained, cmpetent and authrized if they perate cranes; set-up r rig lads; prvide signals fr cntrlling lifts; r inspect, maintain r test cranes, hists, persnnel cages, lifting r rigging equipment. Operatrs f cranes and hists shall be trained and capable f safely perating the histing equipment. There must be a system fr establishing minimum perating time, frequency f peratin and testing t ensure cmpetency fr each class f crane. Task training dcumentatin fr crane peratin must be filled ut as each emplyee is trained. Training dcumentatin is t be sent t the facility recrdkeeping center fr recrding and filing. Kennectt Utah Cpper Crpratin. All rights reserved. The standards n the KUCC Intranet website are cnsidered the standard in effect and supersede all ther revisins.

4 Exhibit KENNECOTT UTAH COPPER CORPORATION PLANNED CRITICAL LIFT PERMIT REV 3 5/04 Permit will be psted at wrk site until wrk is cmplete r a new permit is issued. This permit must be reviewed every shift and reissued if a change in cnditins r wrk scpe has ccurred. This permit and supprting data must be submitted befre any f the fllwing lifts are made (check all that apply): A nn-rutine lift f 20 tns r mre An expected lad lift is 85% r mre f the crane s rated lad capacity A tandem lift Originated By: Crane Operatr: Wrk Descriptin: Cntractr Name: TRACK cmpleted fr this task (Initials): LIFT DATA Date and Time Issued: Wrk Area / Lcatin: Cntractr Supervisr: AM PM 1. Equipment Weight 2. Weight f Rigging 1. 2A. Main Hist Secndary Blck r Ball Blck 2B. Slings Shackles Ttal Rigging Weight: 2A. 2B. 3. Ttal Lift 3A. On Sling (1 + 2B) = Weight 3B. On Crane (1 + 2A + 2B) = 4. Height f Lift 5. Radius f Lift 6. Equipment Surface Area CRANE DATA Nt greater Elevatin sketch shwing height relatin t crane attached? Nt greater Plt plan shwing lcatin and rientatin f crane attached? Maximum subject t Sq. Ft. crsswind N N 1. Crane Manufacturer 2. Mdel and Size 3. Attachments 4. Bumper r Auxiliary Cunterwei ght 5. Bm Length Manufacture s lad chart shwing capacity at varying radiuses and bm lengths attached? Nt greater Lbs. N

5 6. Jib Length Nt greater 7. Lad Blck Size Weight # Sheaves 8. Secndary Blck r Ball Size Weight # Sheaves 9. Main Blck Parts f Line 10. Secndary Blck 11. Mat Size 12. Ntes Parts f Line Beneath each track r fully extended utrigger? Sil bearing pressure (PSF) calculated N Allwable RIGGING DATA 1. Sling(s) Diameter Length Vendr s chart shwing capacity fr different angles and sling cnfiguratins, type f wire rpe and lp splice attached? 2. Briefly describe and sketch sling cnnectin at hk and equipment. Shw dimensins and sling angles. N 3. Shackle(s) Size per shackle Vendr s chart shwing capacity attached? 4. Briefly describe and sketch shackle cnnectins. N 5. Ntes

6 LIFT COMPUTATION 1. Bm Length 2. Radius f Lift 3. Crane 4. Initial rientatin f lift relative t crane 5. Swing rientatin f lift relative t crane 6. Ttal Lift Weight 7. Sling Required 8. Shackle Required 9. Ttal Weight n Slings and Shackles 10. Mat Size Frm manufacturer s chart using cnditins in #1 and #2 f CRANE DATA? Frnt Side Rear Frnt Side Rear Item 3B f LIFT Lbs. DATA Safe wrking lad with hitch cnfiguratin based n tw legs maximum Based n tw legs maximum Item 3A f LIFT DATA Beneath each track r fully extended utrigger N Sil bearing pressure (PSF) calculated Allwable 11. Wind Speed N lifts t be made with wind speeds in excess f MPH 12. Ntes APPROVALS Cntractr Supervisr Acceptance Signature: KUCC Supervisr Acceptance Signature: KUCC Superintendent Acceptance Signature: WORK COMPLETION r CANCELLATION Cmpleted r Cancelled By: Date: Time: PM AM If cancelled, prvide reasn:

7 Exhibit KENNECOTT UTAH COPPER CORPORATION CLOSE PROXIMITY PERMIT (Standard 16.4) RRev. 4 9/04 A Clse Prximity Permit shall be cmpleted and apprved befre cnducting wrk that places equipment that is capable f cming int cntact within: 15 feet f pwer lines; Any fenced substatin; Any wrk area where expsed busses are present. Requested By Plant Wrk Lcatin Department Cntractr (If Applicable) Descriptin f Wrk: TRACK cmpleted fr this task (Initials): Reference Drawing N.: Lcatin: Wrk t be Perfrmed: Brief Descriptin f Interference and Safety Measures t be Taken: Area barricaded Apprved By: Prpsed Wrk Date and Time: Superintendent Electrical Engineering/ Supervisr Safety Equipment Operatr

Crane Mechanic (Limited Scope, Non-Commercial Lift) Competency Checklist and Employer Sign-off

Crane Mechanic (Limited Scope, Non-Commercial Lift) Competency Checklist and Employer Sign-off Crane Mechanic (Limited Scpe, Nn-Cmmercial Lift) Cmpetency Checklist and Emplyer Sign-ff CRANE MECHANIC Date BC Crane Safety Number Name Signature EMPLOYER Date Cmpany Name Cmpany Address Name f Signing