CPM Crane and Lifting Operations Procedure · Web viewOther than for designed lifts, lifting operations using two or more cranes shall use cranes of the same type e.g. telescopic

SINO Iron Project

CPM Cranes and Lifting Operations Procedure

18/09/2019

Uncontrolled document when printed. Printed copy expires one-week from print date.

Refer to Server for current version

Print Date: 31/12/2017

Uncontrolled When Printed

SINO Iron ProjectCPM Cranes and Lifting Operations Procedure

About this document Author/Custodianship

Author: Romana Mecevic Custodian: Gary Rayson

Document details

Document No. DR001919 Revision No.

23.0

IAP Classification

PB Doc. Status Approved

Document revision history

Revision Date Change By Amendment

1.0-19 Refer version history on H&S Portal

20.0 16/07/2018 Gerard Costello Scope Addition of FRM details 8.8 inclusion of load bearing devices Appendix 4 reviewed training requirements

21.0

22.0

10/10/2018

14/11/2018

Gerard Costello

Darryal Kemp

Removal of NDT testing and 12 month minimum experience for inspectionsInclusion of Dynamic Amplification Factor when lifting from/to floating assets.

23.0 30/08/2019 Nick Rowe / Peter Hill

Section 9.1.5 Work over or in close proximity to live plant (i.e. conveyors) with overhead cranes requires a Lift Plan with an associated risk assessment and works supervisor approval.Section 9.3 Barricading and Delineation Procedure requirements to be complied with.Appendix 1 Updated lift table for reviewer and approver

Distribution listThe current approved version of this document can be found on the Health and Safety portal.Updates are distributed in the Daily Safety Alerts (i.e. CPM Site and Contractor Representatives email distribution lists).

For immediate updates of this document, CPM employees can subscribe to Alert Me


Document No: DR001919 Revision: 23.0 Status: Approved Page 2 of 35

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Related Documents

Standards

FRM Standard 01 Lifting Operations DR045278

Procedures

CPM Crane Hoisted Work Box Permit Procedure DR019869

CPM Working at Height Procedure DR001966

CPM Mobile Equipment Isolation Procedure DR001928

CPM Lightning Procedure DR001921

CPM Barricading and Delineation Procedure DR001872

CPM High Voltage – Isolation and Access Procedure DR020600

CPM HS Document and Record Control Procedure DR008575

Forms and Templates

Crane Site Access Approval Checklist DR0045133

Single Crane Lift Study DR004416

Dual Crane Lift Study DR004413

High Voltage Vicinity Certificate DR028023

CPM Overhead Crane Lift Plan DR045132

CPM Crane Register N/A

Australian Standards

Flat synthetic - webbing slings AS1353

Cranes (including hoists and winches) AS1418

Wire rope slings AS1666

Cranes (including hoists and winches) - Glossary of terms AS 2549

Cranes, hoists and winches – Safe use AS 2550

Wedge type sockets AS 2740

Shackles AS 2741

Steel wire ropes AS 3569

Chain slings - Grade T AS 3775

Lifting components for grade T chain slings AS 3776

Round slings – Synthetic fibre AS 4497

Lifting devices AS 4991

Industrial fall-arrest systems and devices AS1891

Electrical Equipment in Mines and Quarries AS 3007.5

National Standard for Licensing persons Performing High Risk Work 2006



http://intranet/English/OperationsAndProjects/Health%20and%20Safety/CITICPacificMiningDocuments/CPM%20Crane%20Hoisted%20Work%20Box%20Permit%20Procedure.doc


National Standard for Plant NOHSC 1010

Other

WA Mines Safety and Inspection Regulations 1995

Worksafe - licencing requirements for operators of vehicle loading cranesDNV-OS-H205 Offshore Standard – Lifting Operations

Document approval

Name Signature Date

Reviewed by Peter Hill PH 30/08/2019

Reviewed by Madeleine Holloway MH 15/09/2019

Reviewed by Nick Rowe NR 30/08/2019

Reviewed by Matt Amos MA 31/08/2019

Approved by

Gary Rayson GR 18/09/2019




Contents

1. Purpose 7

2. Scope 7

3. Definitions 7

4. Responsibilities 9

5. Lifting Operations Safe Systems of Work 10

6. Mobilising Cranes to Site 116.1. Mobilisation of Hired Contractor’s Cranes and Lifting Equipment 116.2. Before first use prior to being put into Service 126.2.1. Inspectors of “Fixed” Cranes and Mobile Cranes 126.2.2. Inspectors of Lifting Equipment 12

7. Registers and Records Requirements 137.1. Crane Records 137.2. Lifting Equipment Register 137.3. Identification and compliance 137.4. Certification 13

8. Maintenance 138.1. Repair/Replacement 148.2. Periodic Inspection and Testing 148.3. Ropes 168.4. Hooks and Hook Blocks 168.5. Spreader Bars (Lifting Beams) 168.6. Attachments 178.7. Removal from Service 178.8. Load Bearing Devices / Supports 17

9. Lifting Operations 179.1. General Requirements 189.1.1. Communication within Lifting Crews 189.1.2. Positioning 189.1.3. Exclusion Zones 189.1.4. Overhead Electrical Conductors 189.1.5. Unprotected Live Plant, Equipment or Services 199.1.6. Adverse Weather Conditions 199.2. Overhead Cranes 199.3. Lift Planning 209.4. Conducting a Pre-Lift Assessment 219.5. Lift Studies / Plans 219.6. Complex Lifts 22




9.7. Lifting operations when the arcs of 2 or more Cranes can overlap 239.8. Multiple Hoist Line or Crane Operations 239.9. Lifting Operations – Port 249.10. Use of hand operated lifting equipment and lifting points 259.10.1. Personnel259.10.2. Equipment 259.10.3. Change 259.11. Loads 269.11.1. Load Test269.11.2. Load Control 269.12. Tag Lines 269.13. Access Areas and Infrastructure 269.14. Pick and Carry 269.14.1. Side Slope Deration 279.15. Riding on Crane Structure 279.16. Suspension of Personnel 279.17. Using other Mobile Plant for Lifting Operations 28

10. Training and Competency 28

Appendix 1 Lift Table – Slewing and Overhead Cranes 31

Appendix 2 Crane Maintenance Schedule 32

Appendix 3 Vehicle Loading Cranes SWL Calculation 33

Appendix 4 Trainer Assessor Qualifications 34

Appendix 5 Crane Mobilisation to Site Process Flowchart 35




1. PurposeThis procedure defines the minimum mandatory requirements for conducting lifting operations safely in all CITIC Pacific Mining Sino Iron Business Units. It covers all lifting operations using cranes and winches.

2. ScopeThe requirements of this document are aligned with Fatality Risk Management Standard 1 – Lifting Operations.

CPM employees and contractor’s involved in cranage, lifting and slinging operations. It is applicable to CPM owned, hired or contracted cranes, including mobile, crawler, tower, derrick, portal and pedestal-type, vehicle mounted cranes, electric overhead travelling cranes, monorail cranes, and associated lifting equipment. This procedure also applies to lifting operations conducted with earthmoving equipment.

This procedure does not cover forklift operations or vehicle hoist operations which utilise 2, 4 or 6 post hoists or chain hoists within a workshop environment.

3. Definitions Term Description

Bridge Crane A crane consisting of a bridge beam or beams that are mounted to end carriages at each end. Capable of travelling along elevated runaways and has one or more hoisting mechanisms arranged to traverse across the bridge.

Competence Demonstrated understanding and application relating to a documented Standard which is personally acknowledged in writing. A competent person means a person who has acquired through training, qualification or experience, or a combination of these things, the knowledge and skills required to complete the task competently.

Crane An appliance intended for raising or lowering a load and moving it horizontally, but does not include an industrial lift truck, earthmoving machinery, an amusement structure, a tractor, an industrial robot, a conveyor, a suspended scaffold or a lift (AS2549).This does not include manually operated lifting devices such as (but not limited to) Chain Blocks and Lever Hoists.

Crane Chart Rated Capacity

The lifting capacity of a mobile crane at a given boom length, boom angle, radius, outrigger configuration and boom (AS1418 Part 5; AS2550) and as per crane manufacturers’ recommendations.

DAF Dynamic amplification factor: A factor accounting for the global dynamic effects normally experienced during lifting from or to a vessel.




Dogging work Applying slinging techniques for the purposes of lifting a load, including selecting the method of lifting (by consideration of the nature of the load, its mass and its centre of gravity) and inspecting lifting gear (for suitability and condition); orDirecting the operator of a crane or hoist in the movement of a load when the load is out of the view of the operator.

Fixed Lifting Equipment Appliances that are a general purpose, permanent fixture to a structure and have been designed to lift loads vertically and / or horizontally. This includes monorail hoists, single lugs and overhead cranes.

High Risk Activity Setup / operating - from a floating structure - from a suspended structure (e.g. bridge) or over water - in a public area Lifts / Lifting - requiring the closure of a public area, footpath or road- near live electrical conductors (cables)- tilt-up precast concrete, precast (cast offsite) facade panels or bridge

beams -using specialised lifting equipment -part of a complex sequence -clearance between the load and boom or boom and surrounding

structures needs to be checked -crane’s arc of operation can intersect that of another crane Demolition work of any type, including the removal of piles Designed lift involving crane modification or a non-standard arrangement Erection of tower cranes Activity involving personnel working in a work box Tree lopping

Vehicle Loading Crane Crane mounted on a vehicle or trailer to load and unload from that vehicle or trailer. May be used for other lifting purposes within its rated capacity.

HRWL High Risk Work Licence.

Lifting Equipment A device used or designed to be used directly or indirectly, to connect a load to a crane, which does not form part of a load. This includes manually operated lifting devices such as Chain Blocks and Lever Hoists.

Lift Study/lift plan Document to plan lifts that include mechanical calculation to assess the safety of critical / heavy lifts to used for both slewing and overhead cranes carrying out nonstandard and complex lifts

MRC Manufacturers Rated Capacity.

Metre tonnage Metre tonnage lifting capacity in relation to Vehicle Loading Cranes. A figure derived by multiplying the lifting capacity by the working radius of the boom or jib for that lifting capacity.

Mobile Crane A crane capable of travelling over a supporting structure without the need for fixed runways (including railway tracks) and relying only on gravity for stability, i.e. with no vertical restraining connection between itself and the supporting surface and no horizontal restraining connection (other than frictional forces at supporting surface level) which may act as an aid to stability (AS2549). This includes all slewing, non-slewing and vehicle loading cranes.

Rigging work Moving, placing or securing a load (such as plant, equipment or members of a building or structure) using mechanical load shifting equipment but does not




include operation of the mechanical load shifting equipment; orErecting or dismantling cranes.

SHL The static hook load (SHL) consists of the gross weight plus rigging weight.

Vehicle Loading Crane Crane mounted on a vehicle for the principal purpose of loading and unloading.

4. ResponsibilitiesRole ResponsibilitiesRegistered Managers

• Ensures that this Procedure is applied across their Registered Mine Site for CPM owned and operated cranes, hired cranes and contracted work.

Area Managers • Line managers understand and adhere to the Procedure• Authorise high risk or complex lifts• Provide sufficient resources to implement the Procedure• Conduct regular inspections and audits of lifting activities

Manager Site Services

• Nominate suitable persons to perform the role of Nominated Crane Approver.

Nominated Crane Approver

• Appointed by the Manager Site Services for the purpose of approving cranes operating on site.

• Inspects all cranes in accordance with this procedure and the Crane Site Access Approval forms.

• Approves cranes that have passed the inspection and have achieved the Lifting standards for CPM crane department.

• Ensures registers of approved cranes are current for the site.• Ensures that each inspected crane has the required Crane Sticker

affixed and that a copy of the inspection form is located in the crane.• Ensures that all cranes are included in the classified plant register.

Crane / Lift Supervisor

• Review lift studies and directly supervise critical or high risk lifting activity as required.

• Providing a completed lift study to be approved by the relevant position in Appendix 1 to confirm the lift is being performed as per design.

• Implementation of the workplace hazard controls as identified in the JHEA or lift study

• The safety of the crew when lifts are performed

Crane Operator • Inspect cranes prior to use• Adhere to requirements for crane set-up• Follow directions as given • Perform daily pre-start check. • Barricade area

Dogman • Select and inspect lifting equipment prior to use • Apply slinging techniques as prescribed • Establish the Exclusion zone




• Direct the Crane operator in the movement of load • Support the Crane Operator in executing lifts

Rigger • Inspect lifting equipment prior to use • Support the Crane Operator in executing lifts • Basic Riggers; quarterly inspection and tagging of rigging and height

safety equipment

Personnel • Obtain approval for lifting activities (Appendix 1)• Conduct a Good to Go and Job Hazard and Environmental Analysis

(JHEA) • Use lifting equipment as per the requirements of the Procedure

5. Lifting Operations Safe Systems of Work Where practicable, the requirement to perform lifting operations shall be eliminated. If required the following shall occur:

lifting operations are classified and planned;

plant and equipment is certified fit for use;

lifting operations are performed only by trained and authorised operators

lifting operations are assessed to identify potential hazards and make sure suitable risk control measures are put in place; and

pre-start inspections are performed prior to use.

Cranes used at Sino Iron must be designed, constructed and tested in accordance with AS 1418 and registered with the State Mining Engineer.

Cranes are managed and operated to the following minimum mandatory requirements:

Cranes are transported to site and erected in accordance with AS 2550.1;

Authorised, competent personnel manage assembly, operation, inspection and maintenance;

Cranes are commissioned in accordance with AS 1418. Operational service commences on receipt of an inspection and testing record signed by a competent person;

Cranes are in parked position when out of service. Access and egress is at designated positions unless the crane is in a breakdown situation. Guidance for safe access is developed for when the crane is at a location other than its designated service position;

Rated capacity of the crane is not exceeded except for the purpose of testing under the supervision of a competent person, or for a designed lift;

Barricades or guards are erected. Personnel must establish voice or visual contact with the Operator if entering a crane’s operating area;




The hook or load is not moved when out of sightline of the operator except when directed by a Dogger / Rigger. The hook or load is raised to avoid collision with any object during horizontal movement;

Out of vertical hoisting is not undertaken;

Moving the load, lifting attachment or other object horizontally, other than when the load is freely suspended, is avoided;

Loads are not lifted over any person;

Slack rope is avoided when landing a load;

Pendant or wireless control -- Operator must have good visibility of the load. Where this is restricted, a Dogger / Rigger are required to direct / support the lift. A clear defined pathway is provided and maintained;

Remote control transmitter must be secured against unauthorised use;

Operating instructions and information on specified operating configurations are provided;

Operators are trained and authorised;

Hand signals and bell, buzzes and whistle signals are used as prescribed in AS 2550.1;

Operators are familiar with the location and operation of the main isolating switch and firefighting equipment. Procedures to manage reasonably foreseeable emergency situations are developed and Operators knowledgeable in their application.

6. Mobilising Cranes to SiteOn first mobilisation to site, a formal selection and acceptance process based on risk assessment shall be in place for all cranes and lifting equipment including contractor’s equipment. Refer Appendix 5.

6.1. Mobilisation of Hired Contractor’s Cranes and Lifting EquipmentCranes shall be inspected and approved for site access and site use by an Appointed “Crane Approver” for that site using DR0045133 Crane Site Access Approval Checklist.

When the Crane Approver has completed the inspection form, information will be recorded on the approved CPM Crane Register and a Site Access Number will be issued which is valid for one year. The Crane Register is a combined document covering all areas, managed by a site Crane Approver. The Crane Register is located in the Cranage and Lifting on the CPM Intranet.

The Inspection sheet for each crane shall be uploaded to the Crane Register.




All cranes shall have displayed a Crane Safe sticker and a Crane Site Access sticker issued after the crane has passed the CPM crane inspection.

The Crane Site Access Sticker indicates the crane has been inspected and approved for use on CPM. The validity period for the Crane Site Access sticker is 12 months.

All mobile crane ropes shall have an in-situ non-destructive rope testing certification completed within the last 12 months.

6.2. Before first use prior to being put into ServiceAll cranes and lifting equipment shall be inspected and tested (as required by the relevant standard) prior to being put into service. After any repair and/or modification, cranes and lifting equipment shall be inspected (as required by the relevant standard) prior to being returned to service.

All mobile cranes (except for Vehicle Loading Crane under 10m/tonne) must have a current Crane Safe Australia Sticker prior to operating at the Sino Iron project.

6.2.1. Inspectors of “Fixed” Cranes and Mobile CranesStatutory Annual Inspections of fixed and mobile cranes shall be carried out by an independent organisation. Such inspections shall be in accordance with the manufacturer’s requirements and AS 2550:3-2002 Cranes, hoists and winches—Safe use Part 3: Bridge, gantry, portal (including container cranes) and jib cranes.

6.2.2. Inspectors of Lifting EquipmentRiggers and Doggers shall carry out a visual inspection of lifting equipment and confirm that it is fit for purpose before use.

Inspectors must hold a Basic Rigger (RB) ticket.

Tags shall be fixed to lifting equipment to demonstrate it has been tested each quarter.

A full list of periodic inspection and testing is found in Table 2.




7. Registers and Records Requirements All cranes and lifting equipment shall be used, maintained, stored and inspected in accordance with the manufacturer’s instructions and the relevant Australian Standards refer to Related Documents at the beginning of this procedure for a list of relevant Australian Standards.

7.1. Crane RecordsAll cranes shall have a register that documents the crane unique identification number. Records to be retained include:

Maintenance performed;

Modifications and tests;

Inspections.

7.2. Lifting Equipment RegisterLifting equipment shall be recorded in a lifting equipment register that contains certification and inspection details.

7.3. Identification and compliance Lifting equipment shall be marked with:

a unique identifier that can be used to track the testing and inspection history of the item;

identifier within correct inspection date; and

working load limit (WLL).

7.4. CertificationLifting equipment shall be certified fit for use by a competent person:

before initial use; and

following major repair or overhaul of load-bearing components.

Lifting equipment shall meet all applicable legislative and Australian Standard requirements.

8. MaintenanceA preventative maintenance system in accordance with OEM manuals shall be conducted and in place to ensure that all cranes, engineered lifting devices and lifting equipment are maintained and in a serviceable condition to the tolerances and specifications as detailed in the maintenance manual. Records shall be maintained.

Inspections, maintenance and repairs are conducted as per AS 2550.1 section 7.




8.1. Repair/ReplacementRepaired or new parts shall be identical or equivalent to manufacturer’s recommendations and specifications. All repairs must be carried out by competent persons under direction and supervision. Modifications to any part of a crane shall not be undertaken without an engineering assessment in compliance to AS 1418.1. Repairs must be tested, documented and recorded.

8.2. Periodic Inspection and TestingLifting equipment used on site shall be regularly maintained and subjected to routine, documented inspections by a competent person. All lifting equipment and accessories shall be inspected, tested and certified by a competent person in accordance with the manufacturer’s instructions and the relevant Australian Standard.

The owner or supplier shall supply inspection and test sheets for all items of lifting equipment before they are used on site.

Additional inspection shall be made if the equipment has been:

involved in an incident; or

modified or repaired.

Records of lifting equipment inspections shall be maintained in accordance with DR008575 CPM HS Document and Record Control Procedure.

Lifting equipment is inspected and tagged with the colour tag identified for the relevant quarter and recorded on the Lifting Register(s). Damaged equipment must be tagged out and quarantined.

Shackles are inspected before and after each use and discarded when the body or pin of the shackle is deformed, or suffers excessive wear

Table 1: Test and Tag Periods

December – February Red

March – May Green

June – August Blue

September – November Yellow

Lifting equipment including the hook block, lifting beams and attachments must be marked in accordance with AS 1418.1. Wire slings, chain sets, soft round slings, chain blocks, lifting beams, shackles and crane hooks must be marked with their safe working load.




Lifting equipment suspended from a crawl beam or jib, which can be removed and replaced, will have the identification number painted on beam in order to prevent incorrect sized equipment to be used. Hook blocks are to be painted to be clearly visible.

Lifting equipment shall be stored in a dedicated storage area off the ground, and protected from damage at all times.

Periodic inspection and testing of cranes and lifting equipment shall be carried out in accordance with Table 2.

Table 2: Inspection and Testing PeriodsInspection& Testing Periods

Requirements

Daily / Pre-Start

Pre-Start Log Book for Cranes completed by the operator at the beginning of each shift OHTC & Monorail Crane Daily Pre/Post Start Inspection ChecklistThe daily inspection forms for OHTC & Monorail cranes shall be completed by the operator prior to use.Integrated tool carrier lifting attachments shall be inspected prior to use.

3 Monthly Inspection

OHTC Powered Monorail Jib CraneLifting Equipment (including engineered lifting devices)Formal recorded inspections of Lifting Equipment shall be carried out by a basic rigger with a minimum of one year experience.Any Lifting Equipment deemed unsuitable for use or missing a test tag must be tagged “Out of Service” to prevent inadvertent use.If lifting equipment is repaired and returned to service it shall undergo a full load test.If lifting equipment is NOT repaired it shall be retired, removed from the register and destroyed. Lifting Attachments (Attachments include Lifting Jibs on the front of Integrated Tool Carriers, Skid Steer Front End Loaders).All lifting equipment must have SWL clearly marked on it.

Annually CPM Site access inspections All slewing and non-slewing cranes All VLC’s Spreader bars

The Crane Safe Statutory inspection and operational tests shall be accepted for all slewing and non-slewing mobile cranes & vehicle loading cranes, OHTC & Powered Monorail & Jib cranes Annual Non Powered Monorails, Jibs Annual Inspection

5 Yearly OHTC, Powered monorails, 100% load test Engineered lifting devices NOTE: NOTE: All non-slewing crane major inspections (as defined in AS 2550) are to be carried out in accordance with AS2550.1 and are reviewed by a professional engineer.




10 Yearly Mobile Cranes, OHTC, Mechanical InspectionNOTE: All non-slewing crane major inspections (as defined in AS 2550) are to be carried out in accordance with AS2550.1 and are reviewed by a professional engineer.

25 Yearly Mobile Cranes, OHTC, Structural InspectionNOTE: All non-slewing crane major inspections (as defined in AS 2550) are to be carried out in accordance with AS2550.1 and are reviewed by a professional engineer.

8.3. RopesCriteria for examination of wire ropes will conform to the crane manufacturer’s guidelines or where not available, AS 2759. A thorough periodic examination is to be carried out by a competent person for wear, damage and corrosion. Particular attention should be paid to the sections of rope close to rigid terminal fittings.

Ropes that are composed of more than one layer of strands, such as non-rotating ropes, may deteriorate internally at the interface between the layers and must be examined. If multi-layer drums are used, the examination shall include part of the rope that is in constant use and the rope that remains spooled and inoperative on the drum.

Boom and fly-jib suspension ropes located remote from the basic crane structure must be examined, particularly those sections lying round sheaves.

8.4. Hooks and Hook BlocksHooks / Hook blocks must be capable of handling the nominated load. The hook will not be loaded beyond its rated capacity. To prevent displacement of the sling or load, the hook should be provided with a safety catch or other effective device to minimise the risk of the sling or load becoming detached.

The hook must not be overcrowded. Where multiple slings are used, they should be attached to a bow-shackle, which is then placed on the hook. All end links, rings or shackles must ride freely on the hook.

8.5. Spreader Bars (Lifting Beams)Spreader bars and lifting beams will be inspected annually by a third party inspection service provider. Structural alterations, including cutting, welding, grinding, non-elastic bending or any form of heat treatment to a spreader bar is not permitted. Altered bars must not be utilised until reinspected by third party certifier.




Three (3) monthly inspections and inspections prior to any lift using this equipment will be undertaken by a competent person and registered in the inspection register.

All spreader bars will be accompanied by their inspection certificates.

8.6. AttachmentsLifting attachments must comply with AS 1418.1 and be clearly and permanently marked.

All lifting attachments must be inspected prior to use. Regular inspections will be conducted by a competent person consistent with the design and usage of the attachments.

8.7. Removal from ServiceLifting equipment shall be removed from service if it is:

damaged;

incorrectly tagged or coded; or

outside the defined inspection date.

8.8. Load Bearing Devices / SupportsAll stand / trestles and support frames that are used for load bearing works need to be designed, labelled, registered with signed approval by a structural engineer or supplied by a manufacturer that will supply certification for the equipment.

9. Lifting Operations The rules detailed below and the associated procedures referenced, shall be applied to lifting operations as follows:

The following shall be ensured:

no person enters the zone of a suspended load;

tag lines are used to prevent the pendulum motion of a load, unless their attachment presents additional risk;

loads are carried as near to the support surface as practicable;

Crane interaction with other cranes (Slewing or other OHC), plant and equipment must be risk assessed prior to task.

lifting operations are stopped if operations are made unsafe.




Cranes shall not be left unattended unless the following actions have been carried out:

all loads have been removed from the hook;

the hook has been raised to a position where it is safely clear of other operations, hooked back or otherwise appropriately secured;

all powered motions have been disabled; and

access to the cabin / controls / remotes are secured.

9.1. General Requirements

9.1.1. Communication within Lifting CrewsCrane Operators and crew must be able to communicate in English and to use correct crane signals. They shall have a dedicated secure radio communication system.

9.1.2. PositioningLifting plant shall be correctly positioned and installed in a clearly defined and protected operational area. Lifting plant shall be positioned to:

minimise the risk of the equipment or load striking a person;

minimise the risk of losing control of the load;

minimise the risk of adversely affecting other plant, structures or underground services; and

ensure all personnel have an unrestricted escape route throughout the entire lifting operation.

9.1.3. Exclusion ZonesExclusion zones shall be implemented to ensure that there is no interaction with other cranes (slewing and or OHC), plant and equipment.

Control measures shall be implemented preventing unauthorised personnel from accessing any area where lifting operations are taking place complying with DR001872 CPM Barricading and Delineation Procedure.

Where personnel are required to enter an area during lifting operations, the operator shall be made aware of their presence by establishing positive communication.

9.1.4. Overhead Electrical Conductors

Workers shall observe safe approach distances / exclusion zones for overhead power lines. Minimum clearances when working near overhead power lines is prescribed in AS 3007.5 Electrical Equipment in Mines and Quarries.




Working within 10 meters falls under the Permit to Work process shall comply with DR020600 CPM High Voltage – Isolation and Access Procedure along with the associated DR024642 CPM High Voltage Vicinity Certificate.

9.1.5. Unprotected Live Plant, Equipment or ServicesA formal risk assessment is required to manage lifting operations near or over unprotected plant, equipment or services, including live process. This includes cranes that extend over, but do not impact on the operations of live plant. The following controls should be adopted where possible:

Assess if isolation of the live plant is practicable;

Dogger and observers as required to monitor safe lateral and vertical clearances between the load and live plant or equipment are maintained;

Working over, or in close proiximity to live plant such as conveyors is classified as a Non-Standard lift and requires a lift study or for overhead cranes a Lift Plan, with an associated risk assessment and crane supervisor approval or works supervisor in the case of lift plans for overhead cranes

9.1.6. Adverse Weather ConditionsWhen wind speeds exceed the maximum figure stated by the crane manufacturer, crane operations should cease. An anemometer should be available at the working site and located to provide an accurate wind load reading on the crane or load.

Where adverse weather conditions (fog and wind causing dust) affect visibility or the communication system, lifting operations will cease until conditions improve.

Outdoor cranes should not be operated during a storm when lightning strikes are reasonably expected. Refer to DR001921 CPM Lightning Procedure.

9.2. Overhead CranesWhen operating overhead cranes, the following must be adhered to:

All crane operators shall be trained and competent in DR030742 Overhead Crane Theory and Practical Assessment and successfully complete the online assessment ‘Bridge Crane – Max 3 Movements’;

Operators must perform a pre-start of overhead cranes prior to use, this includes operational checks are carried out prior to operation and all remote functions including E-stops are operable;

Rigging gear and equipment shall be inspected and checked prior to every use, ensuring they are within their current quarterly inspection check;




The operator must know and understand the crane capacity/Manufacturers Rated Capacity (MRC) and the load to be carried. If the MRC is not clearly displayed on the crane it shall not be used and tagged out of service;

The operator must check the crane operational area/travel for other work groups and hazards prior to use;

When in operation, ensure that safe crane operations are practiced which includes:

Ensure that the hook is over the load;

Take up the weight of the load in slow speed/mode which will reduce the possibility of shock loading on the rope or lifting mechanism;

When stopping, reduce speed slowly, being aware of and allow adequate space/time for the crane to stop. Avoid inching the crane (jogging) as this will increase wear on motors, gearboxes and brake units;

All concentrator bridge cranes are fitted with radar to ensure that cranes cannot collide during simultaneous operation or exceed the common gantry capacity;

All crane operators must consider crane ‘lift plans’ before operating the crane;

Consideration must be made for other cranes on a common rail.

9.3. Lift Planning Lifting operations shall be risk assessed and planned in accordance with Appendix 1 Lift Table.

For repeated or routine operations, such planning is only necessary once, provided that a Job Hazard Environmental Analysis (JHEA) or a Safe Work Instruction (SWI) is in place. Periodic revisions shall be carried out to make sure that no factors have changed.

The planning of all lifting operations shall as a minimum ensure that:

all personnel involved with lifting operations are trained / familiarised;

the travel path is identified and any obstacles are removed before lifting commences;

comply with requirements for lifting operations within the Barricading and Delineation Procedure;

the lifting operation can be executed safely in relation to simultaneous operations;

dynamic amplification factors (DAF) are considered for marine lifting, this may require a lift study.

lifting equipment is suitable and will be used in accordance with the manufacturer’s instructions; and




the lay down area can accommodate the load in terms of size and weight.

9.4. Conducting a Pre-Lift AssessmentA pre-lift assessment is required prior to any lift being conducted. The pre-lift assessment will determine if the lift is classified as a Complex Lift, Non-Standard Lift or Standard Lift. Each of the above categories has certain requirements that must be met prior to conducting the lift.

Complex Lift

The load, including rope, block, rigging etc greater than 75% of the cranes capacity;

The load including rope, block, rigging etc is greater than 50 tonnes (includes OHTC only where the capacity of the crane equals or exceeds 40 tonnes);

There are two or more cranes involved in the lift.

Non-Standard Lift

Hazardous materials or explosives being lifted;

Personnel being lifted by the crane;

The crane be positioned on sloping, rough or unstable ground;

Loads being lifted over building;

Loads being lifted through tight or restricted spaces;

The arcs of two or more cranes likely to interact.

Standard Lifts All other lifts

9.5. Lift Studies / PlansA lift study/plan is a critical control for lifting operations at CPM with specific requirements to ensure the lift is executed in a safe manner. Lift studies/plans are completed as determined by the outcome of the Pre-Lift Assessment, this is a requirement for both slewing and OHC:

Develop and communicate a plan (lifting methodology) to conduct the work safely.

The Crane Operator and Rigger/Dogger must complete a Pre-Lift Assessment for the applicable crane (i.e. JHEA);

Any and all Work Permits must be approved and signed off before the lift commences;

Lift studies/plans are approved by the Lift Supervisor or the Lift Study / Plan Approver (Operations) and/or a qualified Engineer as determined by the Lift Supervisor/crane operator;




The Lift Supervisor/Planner completes Lift Calculation on the applicable Lift Study for single lifts if the load is 75% or more of the Rated Capacity of the Crane at the maximum radius of the lift or 20 tonne. All duel lifts require a lift study regardless of the weights or percentage of crane capacity;

Ground conditions for crane set up have been identified and are appropriate, all underground services have been identified as to set the outriggers;

Ensure adequate lighting is in place where people are working.

Lift Studies must be performed and signed off by all parties identified on the lift study before conducting any multi-crane or high risk lift.

The Lift Study must be reviewed by the Crane Supervisor and a CPM Lift Supervisor and signed off by all parties identified in Section 8 of the lift study. A file is to be kept and made available when requested. Refer Appendix 1 Lift Table.

Refer to DR045132 Overhead Crane Lift Plan, DR004416 Single Crane Lift study, DR004413 Dual Crane Lift study

9.6. Complex Lifts

Lift studies are required to be completed for the following Complex Lifts for slewing and overhead cranes:

When the load is equal to or greater the 75% of the cranes capacity or the weight is 50 tonne or more including block and tackle;

When using more than one crane;

Technical lift (submerged load, load cannot be verified, centre of gravity could change etc.) requiring specialist or engineering input.

A Lift Study / Plan Proforma shall identify requirements for the lift and should be accompanied by (have attached) the following documents or information:

A copy of the Safe Work Instruction/JHEA;

A drawing of the lift and load in its position from lifting to final placement;

Plan view drawings of crane position for the lift;

Lift calculation sheet/s associated with the lift;

Detailed rigging arrangement drawings;

Lift plan / methodology;

The load charts for the lifting crane(s);

The certification for the rigging equipment to be used;




Written detailed weight calculations of the item to be lifted and a drawing of item. Drawings can be Manufactures, CAD or hand drawn;

Details of any design or supply of any custom lifting equipment.

Complex Lift studies must:

be reviewed by all parties identified in the lift study document;

include verification (test lift) of the actual load weight if over 90% and verification of lifting points for all loads;

include a detailed risk assessment.

Once the lift study has been developed and all controls are in place, the crane can operated to its capacity as stated on the cranes load charts.

9.7. Lifting operations when the arcs of 2 or more Cranes can overlapNOTE: This section is applicable to gantry cranes.

The arc of operation refers to the maximum slew radius while the crane is operating. When there is the potential for cranes to be positioned where their maximum slew radius may interact, a formal risk assessment shall to be undertaken to identify all risks involved.

The following minimum controls shall be put in place:

Radio communications to be used between dogman;

Crane operators shall be in radio contact on a secure channel;

Loads shall not be lifted over another crane, if this situation is likely to occur the lower crane must slew out of the way.

Lock out gantry crane or isolate controller when mobile cranes are working in the vicinity (risk of arc overlapping).

9.8. Multiple Hoist Line or Crane OperationsMultiple-crane lifts should be avoided wherever possible. Other than for designed lifts, lifting operations using two or more cranes shall use cranes of the same type e.g. telescopic mobile crane / tower crane and requires a designed Lift Study.

Each crane involved in a multiple-crane lifts must meet the following minimum capacity requirements:

Two-crane lift: 20% greater than the calculated share of the load;

Three-crane lift: 33% greater than the calculated share of the load;

Four (or more)-crane lift: 50% greater than the calculated share of the load.




Where the load is suspended from more than one hoist line, the load shall be handled so that the rated load for each line is not exceeded and the load being handled does not exceed the rated capacity of the crane as indicated.

Advanced Rigger certification is the minimum requirement for multiple hoist line / crane operations.

9.9. Lifting Operations – PortCrane operators performing single crane lifts onto or off the deck of a floating vessel (that may have a vertical motion relative to the crane hook) need to factor in dynamic forces when assessing lifts.

Dynamics will be significantly influenced by parameters such as:

environmental conditions

rigging arrangement

weight of lifted object

All efforts should be made to reduce the relative vertical movement between the crane hook and the floating vessel deck, for example:

The use of a tug boat pushing up on a vessel or creating a lee for a vessel.

Turning vessels to create a lee for lifting operations

If Dynamic forces are considered applicable, it is the crane operator’s responsibility to ensure that the lift can be still be conducted safely and have accounted for Dynamic Amplication Factor in their lift calculation.

Where Dynamic Load Charts are available for a specific crane, these charts can be used in accordance with the manufacturer’s instructions without further reduction in capacity. If Dynamic Load Charts are NOT available, the following Dynamic Amplification Factor shall be applied when using static load charts:

Table 3 – Dynamic Amplification Factor

Static Hook Load (Tonnes) DAF (SHL x DAF)3 – 100 t 1.10

100 - 300 t 1.05

Example SHL of 8 tonne ( 8 x 1.10 = 8.8 tonne)

9.10. Use of hand operated lifting equipment and lifting points Temporary lifting points or devices (chain block, come along, air winch etc.) shall be assessed and approved prior to activities using the criteria below:




For loads less than one tonne, the point or device shall be assessed by a competent person to validate safe lifting practices and the integrity of the point or device;

For loads of one tonne or greater, the lifting point or device shall be load rated (i.e. a certified lifting point or rated via engaging engineering advice).

NOTE: Configurations such as a scaffold tube on a grid mesh floor which is used as an anchor for a sling is not considered to be part of a scaffold structure.

9.10.1. Personnel The lifting Crew will hold a job briefing prior to a lift for which a Lift Study

has been prepared to ensure that all personnel understand how the lift is to be executed.

Ensure personnel are trained in the tasks they are involved with.

Ensure all personnel are fit to conduct the task.

9.10.2. Equipment The equipment is suitable for the task.

Equipment pre-start and pre use checks have been completed.

Barricading is in place as required for the duration of the task.

Lighting is adequate for the task at all times.

Adequate packing or matting for outriggers shall be used.

9.10.3. Change Checks that any changes which have been made in the planning have

not introduced additional risk.

Environmental conditions have been considered.

Are any changes about to be made:

- Different equipment to be used;

- Work area modification (e.g. traffic management);

- New hazards in the area.

9.11. Loads

9.11.1. Load TestCranes will not handle any load greater than the rated capacity. Load testing of the winching system is conducted on every shift for the first load and the first load that is greater than 50% of the rated capacity.




Unnecessary operation of motion limits will be avoided unless usage is to a functional limit where a final limit is fitted.

9.11.2. Load Control When hoisting a load, ensure that:

slings are applied to the load and the crane hook; no part of the load is loose; load is free and ready for hoisting; load will not foul any object; load will not constitute a hazard to any personnel; load placement area is ready to receive the load.

9.12. Tag LinesTag lines are used on all loads unless approved through a task specific risk assessment. Hand or tag lines must be at least 16 mm in diameter, made of nonconductive material and sufficient length to complete the job. Tag lines are maintained and inspected before use. Lifting equipment is not to be used as tag lines. Taglines must not be attached to the lifting equipment.

9.13. Access Areas and InfrastructureHandling of loads over / around public access areas should be avoided. If unavoidable, position barricades and maintain a safe operating area beneath the crane. Buildings should be cleared if the lift radius is over any occupied buildings.

9.14. Pick and CarryNon-slewing cranes and crawler mounted cranes may be used for pick and carry operations. Rubber tyre slewing cranes are permitted to be used for pick and carry operations only if their load chart permits it and their slew motion is capable of being locked to prevent slewing during the carrying operation.

Loads shall be tied back to the crane during pick and carry operations, the Dogger/Rigger shall not hold onto the load unless in a restricted area.

Vehicles with flashing lights shall be the preferred method of escorting pick and carry operations. Where a Dogger is used to escort the pick and carry operation on foot, they shall be in front of and to the side of the crane out of its path and in full view of the crane operator. All pick and carry operations shall be conducted in crane mode (low speed).

Trucks shall be used for moving and carrying loads over long distances; mobile cranes shall not be used for this purpose.




9.14.1. Side Slope DerationAll non-slewing rubber tyre pick and carry cranes are affected by side slope deration. Side slope deration will reduce the SWL and stability of the crane considerably. Manufactures load charts must be available and in the crane during operations. If no side slope deration charts are available for the crane, the crane shall not operate on all CPM sites. A Crane inclinometer shall be fitted to the crane and be functional at or times. Where possible the inclinometer should be colour coded as to align to the cranes specifications.

9.15. Riding on Crane StructurePersonnel are to be accommodated in the crane cabin or on the work platform during crane operations, unless conducting maintenance, commissioning, erection or dismantling.

9.16. Suspension of Personnel Workboxes shall only be used where it is not reasonably practicable to use scaffold or other specifically designed temporary work platforms, refer to DR001966 CPM Working at Height Procedure.

Personnel shall only be lifted in workboxes designed according to AS 1418.17:1996 Cranes (including hoists and winches) – Design and construction of workboxes and are used in accordance with AS 2550.1:2011 Cranes, hoists and winches.

A least one person in the workbox shall hold as a minimum a dogger’s licence to make sure correct directions are communicated to and from the crane operators. Radios with dedicated channels shall be used where there is limited or no ‘line of sight’ between the dogger and the crane operator.

Workboxes are to be fitted with suitable anchorage point capable of withstanding the fall forces specified in AS/NZS 1891.4:2009 Industrial fall-arrest systems and devices – Selection, use and maintenance.

Personnel working in workboxes shall use a fully compliant fall arrest / restraint harness system unless the workbox is fully enclosed. Workboxes and sully boxes shall not be suspended over people.

Workboxes, lifting attachments and records shall be checked by a competent person before use to make sure the workbox or is fit for purpose and securely attached to the crane.

Workers shall be prohibited from entering or leaving the workbox when it is suspended (except in an emergency).

A workbox shall not be used unless the crane it is proposed to be suspended from is fitted with the means to safely lower it in an emergency or a power supply failure.




The crane suspending a workbox shall:

have and use ‘drive up’ and ‘drive down’ controls on both hoisting and luffing motions;

NOT be de-clutched allowing free fall; and

be fitted with an operational anti-two block (upper hoist limit).

Mobile cranes shall not travel while people are in the workbox, unless in the immediate work area and movement is required to safely perform the required work.

The operator must remain at the controls of a crane suspending a workbox.

The DR021735 Crane Hoisted Workbox Certificate shall be completed and approved prior to any suspension of personnel.

9.17. Using other Mobile Plant for Lifting OperationsOther mobile plant shall be used for lifting operations only if:

the equipment is designed and certified for use in lifting operations;

mobile plant with a lifting capacity exceeding one tonne is fitted with burst protection valves; and

locking pins are used on quick-hitches.

Mobile plant used for lifting operations shall be operated in accordance with manufacturer’s recommendations.

10. Training and CompetencyPersonnel operating cranes or using lifting equipment must be trained, assessed and verified as competent. Assessment and Verification of Competency (VoC) is only performed by Assessors authorised to perform High Risk Work Licence assessment (Appendix 4).

Licences and competencies are reassessed at intervals determined by Worksafe WA High Risk Work Licence (HRWL).

Evidence of structured competency-based training certification is required for classes:

DG - Dogging RB - Basic rigging RI - Intermediate rigging RA - Advanced rigging CB – Bridge/Gantry crane CV – Vehicle loading crane CN – Non slewing crane




C2 – Slewing and mobile crane up to 20 tonnes C6 – Slewing and mobile cranes up to 60 tonnes C1 – Slewing and mobile cranes up to 100 tonnes CO – Slewing and mobile cranes open/over 100 tonnes

A Basic Rigging certificate is the minimum qualification for tasks requiring the use of mechanical load-shifting devices such as chain blocks, lever hoists and winches.

For lifting a load less than one tonne, where complex lifting techniques are required, the worker performing the lifting operation must hold a HRWL as a Dogger or Rigger and have also completed the required familiarisation.

For lifting a load equal to or over one tonne the worker performing the lifting operation must hold a HRWL as a Dogger or Rigger and have also completed the required familiarisation.

A HRWL for crane operation is required to operate vehicle loading cranes with a lifting capacity of 10 metre tonnes or greater (Appendix 3). A Dogging / Rigging ticket is required if the load require slinging from other than fixed lifting points.

Exemptions

A competent person is able to sling a load, without holding a dogging HRWL (or rigging) for lifts up to one tonne when there is no judgement required for slinging techniques or the suitability and the condition of lifting gear because the following factors are predetermined:

the weight of the load (or within a weight range) to be lifted is predetermined by a competent person (e.g. may be marked on the load);

selection of the sling and slinging techniques for the load is predetermined by a competent person;

the condition of lifting gear is predetermined by a competent person;

the lifting points are predetermined by a competent person and marked on the load;

the load is lifted within the view of the operator at all times; and

standard lifting procedures have been documented and signed-off by a competent person.

Personnel will be required to evaluate and apply the criteria of the exemption via various methods, including relevant familiarisations and risk assessment tools (such as the use of JHEA, SWI etc).




Appendix 1 Lift Table – Slewing and Overhead Cranes

CLASSIFICATION CRITERIA ACTION REVIEWED APPROVAL

Standard LiftLoad less than 20 TonneLoad less than 75% of chart capacityIs not a non-standard or critical lift

Good To Go / JHEA N/A Crane Operator

Non-Standard Lift

Load greater than 20 Tonne but less than 50 TonneLoad greater than 75% Is not critical liftLoad is supported or balanced using chain blocks that exceeds 85% of the chain block capacityLoad lifted over or near live plant (such as conveyors) or overhead power lines

Lift Study (Slewing) /Lift Plan (OHC) Crane Supervisor

Crane OperatorCrane Supervisor

Lift Plan (OHC) Crane Operator and Rigger Works Supervisor

Complex Lift

Load greater than 50 Tonne Load greater than 75% of chart capacityMore than one crane is utilisedLifts over critical plant.Special lifting equipment or non-standard crane configuration

Lift Study /Lift Plan with detailed Rigging plan and diagram or lift plan for gantry cranes (OHC)

CPM Senior Crane OperatorCrane Supervisor

CPM Crane / Lift Supervisor




Appendix 2 Crane Maintenance Schedule

Crane classification C1 C2 C3 C4 C5 C6 C7 C8

M1 M2 M3 M4 M5 M6 M7 M8

Operating hours/day ≥0.5 0.5-1 >1-2 >2-4 >4-8 >8-16 >16 >20

Routine maintenance weeks 12 12 12 12 8 8 4 4

Periodic third party inspection/weeks 52 52 52 52 52 52 52 52




Appendix 3 Vehicle Loading Cranes SWL Calculation

The ten metre tonnes is calculated by MULTIPLYING THE SWL x THE WORKING RADIUS FOR THAT SWL= METRE TONNES from the centre line of slew to the centre line of hook. This calculation must be done for each safe working load (SWL) on the load chart. If the calculation amounts to 10 metre tonnes lifting capacity or greater, the crane operator will require the appropriate High Risk Work Licence.

X 1 Tonne 1.5 tonne 2 tonne 2.5 tonne 3 tonne1m 1 1.5 2 2.5 3

1.5m 1.5 2.25 3 3.75 4.52m 2 3 4 5 6

2.5m 2.5 3.75 5 6.25 7.53m 3 4.5 6 7.5 9

3.5m 3.5 5.25 7 8.75 10.54m 4 6 8 104.5 4.5 6.75 95m 5 5.75 105.5 5.5 8.256 6 9

6.5m 6.5 9.757m 7 10.5

The area’s highlighted red in indicate lifting capacities that are 10 metre tonnes and above. In these instances the crane operator will require a HRWL.




Appendix 4 Trainer Assessor Qualifications Qualification Requirements

Assessor

Certificate IV in Assessment and Workplace Training TAE40104

CPM Authorised Trainer/Assessor

Qualified on or hold the appropriate licences to undertake the assessment

OR

Enterprise Skill Set Training and Assessment Qualifications; TAEASS401B, TAEASS402B, TAEASS403B, TAEDEL301A

CPM Authorised Trainer/Assessor Qualified on or hold the appropriate licences to undertake the assessment

Slewing / Mobile cranesHold the appropriate HRWL licence for a minimum period of 6 months

CPM Authorised Trainer/Assessor (CPM Personnel only)

Bridge and Mono rail cranesHold the competency for a minimum period of 3 months at CPM

CPM Authorised Trainer/Assessor (CPM Personnel only)




Appendix 5 Crane Mobilisation to Site Process Flowchart


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