017-10-30 1 of 13 Training Code Document Owner: Name: Dave Duczeminski Position: Manager Department: Maintenance Engineering Table of Contents 1.0 PURPOSE....0 SCOPE....1. EXCEPTIONS... 3.0 REFERENCES... 3 4.0 DEFINITIONS... 4 5.0 CATEGORIZING A LIFT... 6 5.1. MOBILE CRANE LIFT CATEGORIES... 7 5.. FIXED CRANE LIFT CATEGORIES... 8 6.0 LIFT PLANS... 9 6.1. CRITICAL LIFT... 10 6.. NON-STANDARD LIFT... 10 6.3. STANDARD LIFT... 10 APPENDICES... 11 Appendix A: Revision Notes and Approvals... 1
017-10-30 of 13 1.0 PURPOSE This standard document describes the process to be used to: a) classify a mobile or fixed crane lift activity into one of three categories according to its level of risk and complexity, and b) identify the level of training and planning required for the lift. This standard should be referenced in conjunction with the following standard documents: MSPEC-7000 Rigging Training Levels MGUID-70003 Lift Plan Guideline Standard documents are available on the Ontario Operations Maintenance Standards Website at the following URL: http://extportal.vale.com/maint/sud/.0 SCOPE This procedure is applicable to all Vale employees conducting lifting and mechanical handling activities within Vale s Ontario Operations..1. EXCEPTIONS This procedure IS NOT applicable to: Production lifts Engineered lifts Lifts of personnel with a crane or hoist Horizontal pulls (towing) These lift categories are outside the scope of this standard. This procedure does NOT prescribe the minimum training, trade qualification, or licensing required to qualify an employee to operate or drive a crane or any other mechanical lifting equipment/device.
017-10-30 3 of 13 3.0 REFERENCES The following references were used in the development of this document or are related to it. They shall be used in their most recent revision. Hoisting and Rigging Safety Manual, Infrastructure Health & Safety Association, 1995 manual available at https://www.ihsa.ca/pdfs/products/id/m035.pdf Vale Critical Activities Requirements - PTP-000813, Rev.:01 6/01/016, Section: CAR- 05 Lifting of Loads MSPEC-7000 Rigging Training Levels MGUID-70003 Lift Plan Guideline Vale HomeSafe Program Vale Golden Rule #5
017-10-30 4 of 13 4.0 DEFINITIONS Authorized: permission to perform a specific task given by a supervisor who is in charge of the workplace. CBT: computer based training. Competent Person: a person who (a) is qualified because of knowledge, training and experience to organize the work and its performance, (b) is familiar with the Act (Ontario Occupational Health and Safety Act) and the regulations that apply to the work, and (c) has knowledge of any potential or actual danger to health or safety in the workplace. [OHSA Section 1] Critical Lift: a lift category where the lift requires comprehensive planning, including formal risk assessment, to minimize the potential of crane failure and/or catastrophic loss due to the elevated risks associated with the lift operation: i.e. characteristics of the load, path of the lift, environmental conditions the lift must be executed within i.e. a mobile crane lifting a load greater than 10 tons, or a fixed crane lifting a load where the hazards can have significant impact to the business i.e. slinging in a mine shaft. The process for categorizing mobile and fixed crane lifts is defined in maintenance standard:. Engineered Lift: a lift activity that takes into account special situations when the lifting of the load exceeds the manufacturer's hoist or crane capacity and where the lift must be carried out under controlled conditions in accordance with a lift plan prepared by a Professional Engineer. JHA Job Hazard Analysis: a formal risk assessment tool that helps us identify hazards, analyze/evaluate the risk associated with that hazard, and determine the appropriate way to eliminate or control the hazard. Lift: a single operation in which a load is rigged, hoisted and moved from one position to another. Lift Plan: a plan (written or verbal) that outlines the number of people required to complete the lift, the lift and rigging equipment required, how the load will be rigged, the lift method to safely lift and move the load, risks that might be encountered as well as the controls to manage the risks etc. NOTE: This list is not exhaustive. For guidance on key components of a lift plan refer maintenance standard: MGUID-70003 Lift Plan Guideline.
017-10-30 5 of 13 Non-standard Lift: a lift category where the lift operation cannot be accomplished using a known standard process, common method, materials or equipment. i.e., where the weight of the load is unknown and must be calculated or estimated and customized or specialized rigging of the load is required e.g. a Boom Truck Operator needing to rig and lift an awkwardly shaped item such as a large fan impeller. The process for categorizing mobile and fixed crane lifts is defined in maintenance standard:. PHR Process Hazard Review: a formal risk assessment tool that helps us identify hazards, analyze/evaluate the risk associated with that hazard, and determine the appropriate way to eliminate or control the hazard. Production Lift: a lift that is repetitive and routine, related to a production process, performed by a qualified and competent crane operator following established procedures and processes i.e. crane operator executing lifts in the Smelter converter aisle. Rigging: a process of applying ropes, cables, chains and/or attachments to secure a load to be moved by cranes or other lifting equipment. Risk: is the likelihood that an accident can occur due to a hazard and as a result, how badly someone is hurt. This largely depends on the implementation of control measures, the working conditions of the control measures and site conditions. For example, a control measure that is higher up on the hierarchy of control (such as engineering controls) would result in a lower risk. Risk Assessment: a formal process used to identify hazards, analyze or evaluate the risk associated with the hazards, and determine appropriate ways to eliminate or control the risks. SLAM STOP / LOOK / ASSESS / MANAGE: a risk assessment tool within Vale s HomeSafe program. It reminds employees to stop, look, assess and manage risks to achieve zero harm and ensure they go HomeSafe at the end of every shift. SLAM also helps employees identify non-routine activities and/or abnormal conditions that require a more formal risk assessment such as a Job Hazard Analysis (JHA) or Process Hazard Review (PHR). Standard Lift: a lift category where the lift operation can be accomplished through a standard process, using a common method, materials and equipment. The load has known or evaluated weight, shape and center of gravity. The radius at which the load must be handled is within the rated capacity of the crane at that radius. The lift is performed under normal environmental conditions. Standard rigging and lifting equipment is used i.e. Mill Circuit Operator loading balls. The process for categorizing mobile and fixed crane lifts is defined in maintenance standard:.
017-10-30 6 of 13 5.0 CATEGORIZING A LIFT Mobile and fixed crane lifts shall be classified into one of the following three categories of lifts: Standard Lift: a lift that can be accomplished through a standard process, using a common method, materials and equipment. The load has a known or evaluated weight, shape and center of gravity. The radius at which the load must be handled is within the rated capacity of the crane at that radius. The lift is performed under normal environmental conditions. Standard rigging and lifting equipment is used. i.e., Mill Circuit Operator loading balls Non-standard Lift: a lift that cannot be accomplished using a known standard process, common method, materials or equipment. i.e. where the weight of the load is unknown and must be calculated or estimated and customized or specialized rigging of the load is required e.g. a Boom Truck Operator needing to rig and lift an awkwardly shaped item such as a large fan impeller Critical Lift: a lift that requires comprehensive planning to minimize the potential of crane failure and/or catastrophic loss due to the elevated risks associated with the lift: i.e. characteristics of the load (weight, size, shape, value, hazard), path of the lift, environmental conditions the lift must be executed within i.e., a mobile crane lifting a load greater than 10 tons, or a fixed crane lifting a load where the hazards, if encountered, can have significant impact to the business i.e. slinging equipment in a mine shaft The next sections provide charts to help guide you in categorizing mobile and fixed crane lifts. The charts identify the criteria used to categorize a lift, requirements for written lift plans, and the rigging training level required by a Vale employee to be qualified to rig a load for the different categories of lifts. If after risk assessment you cannot control a risk to achieve Zero Harm, if you are uncertain about the effectiveness of a control, or if you are uncertain as to the category of lift you are rigging a load for, STOP and refer to your Supervisor. For details on training requirements to be qualified to conduct below-the-hook rigging for each of the lift categories refer to standard document: MSPEC-7000 Rigging Training Levels.
017-10-30 7 of 13 5.1. MOBILE CRANE LIFT CATEGORIES Mobile cranes include wheel-mounted cranes, crawler cranes, vehicle-mounted cranes, boom truck, tow cranes etc. 1. Lifting a load under circumstances that are outside the manufacturer s equipment specification. Lifting a load where the crane is on unstable ground, not level, operating on a barge, or lifting to or from water Yes No Rigging Training Level * If any of the above conditions apply, STOP, this lift requires formal risk assessment/planning i.e., engineering. Refer to your Supervisor for further direction. If NONE of the above conditions apply, review the next set of conditions: 3. Lifting a load in excess of 10 tons Level III 4. Lifting a load over operational processes or facilities deemed critical to the plant s operations ( critical as defined by the plant) e.g. gas lines, mine hoist, reactors etc. that if damaged would negatively impact safety, Level III health, environment or production 5. Lifting a load over or in proximity to electrical power lines Level III 6. Lifting a load where two or more pieces of lifting equipment are required to work in unison (tandem lift) i.e. move, drift or transfer the load from one lifting device to another Level III 7. Lifting a total load equal to or greater than 75% of the manufacturer's hoist or crane capacity, as shown on the load charts for the configuration, including the maximum radius that will be experienced Level III 8. Lifting a load that needs to be maneuvered through a space with minimal clearances Level III 9. Lifting where the load is out of sight of the crane operator and requiring a signal person to help direct the movement of the load e.g. lifting a load through an opening in the roof of a building Level III If ANY of conditions 3 to 9 apply, this is a CRITICAL LIFT A written LIFT PLAN (or procedure) approved by Superintendent (or designate) is required to be reviewed/signed off by lift team members A formal risk assessment required. Attach copy of risk assessment to the Lift Plan If NONE of the above conditions apply, continue to review the next set of conditions: 10. Lifting a load with an awkward shape, unbalanced weight, unknown or difficult to estimate weight or unknown center of gravity i.e. a fan impeller Level II 11. Lifting a load that requires a customized, non-standard, specialized rigging arrangement i.e. using come-a-longs, chain falls or other lifting devices incorporated in the lift arrangement Level II 1. Lifting a load where environmental conditions are likely to affect the lift execution e.g. non-temperate environmental conditions such as wind, rain, sloping terrain, high noise areas, poor visibility (fog, rain, darkness Level II or dust) If ANY of conditions 10 1 apply this is a NON-STANDARD LIFT Perform a HomeSafe risk assessment starting with a SLAM and if required move to additional levels of assessment i.e. JHA A written lift plan (or procedure) is recommended but not mandatory If NONE of the above conditions apply, continue to review the next set of conditions: 13. The lift is conducted frequently (part of a regular job routine) and is accomplished using a known standard work process, common method, and standard rigging and lift equipment that you are trained and qualified to Level I apply/operate 14. The load being lifted has known weight, shape, and center of gravity Level I 15. The load is within the rated capacity of the crane at the boom angle and radius for the lift Level I 16. The lift is to be conducted in normal working conditions i.e. temperate environmental conditions Level I If ALL of conditions 13 to 16 apply, this is a STANDARD LIFT Complete a HomeSafe SLAM risk assessment A written lift plan is not required, follow standard work process If ANY of conditions 13 to 16 are NO and you are unable to categorize the lift into any of the above categories, refer to your Supervisor. Level I
017-10-30 8 of 13 5.. FIXED CRANE LIFT CATEGORIES Fixed cranes include electric overhead trolley cranes, jib cranes, gantry cranes, mine hoists etc. 1. Will you be lifting a load that is part of a routine production lift following an established standard process which you have been trained, qualified and authorized to perform as a normal part of your regular duties? Yes No Rigging Training Level * Plant specific If YES, this is a PRODUCTION LIFT. A formal written LIFT PLAN is not required. Follow standard operating procedures. If none of the above conditions apply, continue to review the next set of conditions:. Will you be lifting a load under circumstances that are outside the lift equipment manufacturer's specifications? If the above condition applies, STOP, this lift requires formal risk assessment/planning i.e., engineering. Refer to your Supervisor for further direction. If the above condition does NOT apply, review the next set of conditions: 3. The risks related to the lift have significant impact to the business e.g. slinging in a mine shaft, or lifting over operational processes or facilities deemed critical to the plant's operations ( significant and Level III critical defined by the plant) 4. Lifting where the load is out of sight of the crane operator and requiring a signal person to help direct the movement of the load Level III If ANY of conditions 3 to 4 apply, this is a CRITICAL LIFT A written LIFT PLAN (or procedure) approved by Superintendent (or designate) is required to be reviewed/signed off by lift team members A formal risk assessment required attach copy of risk assessment to the Lift Plan. If NONE of the above conditions apply, continue to review the next set of conditions: 5. Lifting a load with an awkward shape, unbalanced weight, unknown or difficult to estimate weight or unknown center of gravity i.e. a fan impeller Level II 6. Lifting a load that requires a customized, non-standard, specialized rigging arrangement i.e. come-alongs, chain falls or other lifting devices incorporated in the lift arrangement Level II 7. Lifting a load where environmental conditions are likely to affect the lift execution e.g. non-temperate environmental conditions such as wind, rain, sloping terrain, high noise areas, poor visibility (fog, rain, Level II darkness or dust) If ANY of conditions 5 7 apply this is a NON-STANDARD LIFT Perform a HomeSafe risk assessment starting with a SLAM and if required move to additional levels of assessment i.e. JHA A written lift plan (or procedure) is recommended but not mandatory If NONE of the above conditions apply, continue to review the next set of conditions: 8. The lift is conducted frequently (part of a regular job routine) and is accomplished using a known standard work process, common method, and standard rigging and lift equipment that you are trained Level I and qualified to apply/operate 9. The load being lifted has known weight, shape, and center of gravity Level I 10. The load is within the rated capacity of the crane Level I 11. The lift is to be conducted in normal working conditions i.e. temperate environmental conditions Level I If ALL of conditions 8 to 11 apply, this is a STANDARD LIFT Complete a HomeSafe SLAM risk assessment A written lift plan is not required If ANY of conditions 8 to 11 are NO and you are unable to categorize the lift into any of the above categories, refer to your Supervisor. Level I
017-10-30 9 of 13 6.0 LIFT PLANS All lift operations require some level of planning, including an assessment of the potential hazards and risks. The level of planning required depends on the unique characteristics of the lift. Lift plans can be written or verbal. At Vale, a lift categorized as a critical lift requires a written lift plan inclusive of a formal risk assessment. Refer to Section 6.1 Critical Lift in this document for further details. A written lift plan can be formalized in a lift plan job procedure. Lift plans shall be reviewed with lift team members prior to the lift to ensure it is understood by all those executing the lift, nothing has changed since the plan was developed, and the lift plan remains valid. The following list outlines key components in a lift plan. The list is not exhaustive. Purpose of the lift, item to be lifted, date and location of lift Crane details Load/Lift calculations Rigging details Lift team Set up, layout, sequence of event sketches Communication details Risk assessment hazards and controls Lift day checklist Approval Signatures (as is applicable) For guidance in creating a written lift plan, refer to maintenance standard: MGUID-70003 Lift Plan Guideline. This standard provides access to a Lift Plan template (in WORD format) for your use.
MAINTENANCE STANDARD PROCEDURE 017-10-30 10 of 13 6.1. CRITICAL LIFT A critical lift requires a written lift plan supported by a formal risk assessment. The lift plan shall be prepared by a competent, qualified person knowledgeable in the lift equipment, rigging and load to be lifted. The lift plan is to be reviewed and approved by the Superintendent (or designate). The critical lift plan inclusive of the HomeSafe risk assessment shall be reviewed and signed off by those involved in the lift activity at a pre-lift meeting. The purpose of this meeting is to ensure the lift plan, as documented, is understood by all those executing the lift, nothing has changed since the plan was developed, and the plan remains valid. 6.. NON-STANDARD LIFT A non-standard lift requires additional detailed planning to address the non-standard nature of the lift; and while a written lift plan is not mandatory, it is recommended. Non-standard lift planning includes using the HomeSafe risk assessment tool to determine the level of risk assessment required. The lift plan inclusive of the HomeSafe risk assessment shall be reviewed by all those involved in the lift activity prior to executing the lift to ensure it is understood by all those executing the lift, nothing has changed since the plan was developed, and the plan remains valid. 6.3. STANDARD LIFT A standard lift involves following a standard work process and uses the HomeSafe risk assessment tool to determine the level of risk assessment required. The standard process/method used to conduct the lift, supported by the HomeSaferisk assessment, shall be reviewed by those involved in the lift prior to executing the lift.
MAINTENANCE STANDARD PROCEDURE 017-10-30 11 of 13 APPENDICES APPENDIX A: Revision Notes and Approvals
MAINTENANCE STANDARD PROCEDURE 017-10-30 1 of 13 Appendix A: Revision Notes and Approvals The revision notes are a summary of the changes and may not necessarily be a complete list. Revision Notes Last revised by: Garwin Pitman, Dan Jeanveau and Janet Herman. Reviewed with Ontario Maintenance Leadership Group. Risk(s) have been addressed for this revision by the reviewers and approvers and are determined to be low or no new hazards identified. Revisions: 1.0 Purpose - b) Modified wording to indicate standard s purpose is to identify the level of training and planning required for a lift. 5.0 Categorizing A Lift The categorization charts are used to identify the requirements for written lift plans and rigging training levels required. Removed wording that indicated they identify requirements for risk assessments. Risk assessments follow Vale s HomeSafe Program. 5.1 Mobile Crane Lift Categories and 5. Fixed Crane Lift Categories Revised wording on type of risk assessment required to read: Perform a HomeSafe risk assessment starting with a SLAM and if required move to additional levels of assessment i.e. JHA 6.1 Critical Lift and 6. Non-Standard Lift and 6.3 Standard Lift - Removed references to type of risk assessment to be used. All lift plans require a risk assessment the level of risk assessment defined in our HomeSafe Program risk assessment tools this is clarified in each section. 1 New Standard: Risks have been addressed for this new standard by the reviewers and approvers. Low risk or no new hazards identified. The requirements outlined in this specification were reviewed and approved by the Ontario Leadership Team at its September 1, 017 meeting.
MAINTENANCE STANDARD PROCEDURE 017-10-30 13 of 13 Document Review & Approvals Name and Positions Dated Document Owner Dave Duczeminski, Manager Maintenance Engineering On behalf of the Maintenance Managers Leadership Group Ontario Operations Dave Duczeminski, Manager Maintenance Engineering (Mines) Glen O Neil Maintenance Engineering (Surface) Oct 3, 017 Ontario Operations Bruce Bichel, Manager Production Services and Support