TRAINING & DEVELOPMENT LIFTING AND MECHANICAL HANDLING ...extportal.vale.com/maint/Sud/pdf/MSPEC-70002.pdf · maintenance standard specification ontario operations title training

MAINTENANCE STANDARD SPECIFICATION ONTARIO OPERATIONS

TITLE

TRAINING & DEVELOPMENT LIFTING AND MECHANICAL HANDLING Rigging Training Levels

VALE #

MSPEC-70002

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2016-12-19

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Training Code

Document Owner: Name: Dave Duczeminski Position: Manager Department: Maintenance Engineering

Table of Contents

1.0 PURPOSE....................................................................................................................................................................... 2

2.0 SCOPE ........................................................................................................................................................................... 2

2.1. EXCEPTIONS ................................................................................................................................................................ 2

3.0 REFERENCES .................................................................................................................................................................. 3

4.0 DEFINITIONS ................................................................................................................................................................. 4

5.0 QUALIFICATION TO RIG ................................................................................................................................................. 6

5.1. QUALIFICATION THROUGH VALE RIGGING TRAINING ............................................................................................................ 6 5.2. QUALIFICATOIN THROUGH OCCUPATIONAL TRADES TRAINING .................................................................................................. 6

6.0 VALE RIGGING TRAINING .............................................................................................................................................. 7

6.1. LEVEL I – RIGGING TRAINING .............................................................................................................................................. 7 6.2. LEVEL II – RIGGING TRAINING ............................................................................................................................................. 8 6.3. LEVEL III – RIGGING TRAINING ....................................................................................................................................... 9

7.0 TRAINING RECORDS .................................................................................................................................................... 10

7.1. REFRESHER TRAINING ..................................................................................................................................................... 10

8.0 APPENDICES ................................................................................................................................................................ 11

Appendix A: Revision Notes and Approvals ....................................................................................................................................... 12


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MSPEC-70002

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1.0 PURPOSE This specification prescribes the minimum training or trade qualification required by a Vale employee to conduct below-the-hook rigging activities. This document should be referenced in conjunction with the following standard documents:

• MPROC-70001 Categorizing Mobile and Fixed Crane Lifts • 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/

2.0 SCOPE This specification is applicable to all Vale employees conducting lifting and mechanical handling activities within Vale’s Ontario Operations.

2.1. EXCEPTIONS This specification 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 specification 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.

http://extportal.vale.com/maint/Sud/


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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 26/01/2016, Section: CAR-05 – Lifting of Loads

MPROC-70001 Categorizing Mobile and Fixed Crane Lifts

MGUID-70003 Lift Plan Guideline

Vale HomeSafe Program

Vale Golden Rule #5

https://www.ihsa.ca/PDFs/Products/Id/M035.pdf


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VALE #

MSPEC-70002

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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: MPROC-70001 Categorizing Mobile and Fixed Crane Lifts. Engineered Lift: a lift operation 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.


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MSPEC-70002

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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: MPROC-70001 Categorizing Mobile and Fixed Crane Lifts. 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: MPROC-70001 Categorizing Mobile and Fixed Crane Lifts.


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5.0 QUALIFICATION TO RIG

5.1. QUALIFICATION THROUGH VALE RIGGING TRAINING At Vale, below-the-hook rigging training is provided to employees at three levels:

• Level I Rigging – Rigging for Standard Lifts • Level II Rigging – Rigging for Standard and Non-Standard Lifts • Level III Rigging – Rigging for Standard, Non-Standard and Critical Lifts

The process for categorizing mobile and fixed crane lifts is defined in maintenance standard: MPROC-70001 Categorizing Mobile and Fixed Crane Lifts.

5.2. QUALIFICATOIN THROUGH OCCUPATIONAL TRADES TRAINING The following tradespersons, based on occupational trades training, are considered to have the following levels of training and are therefore qualified to conduct rigging activities as follows:

VALE RIGGING TRAINING

LEVEL I LEVEL II LEVEL III

OCC. CODE

TRADE CLASSIFICATION Standard Lifts

Standard and Non-Standard Lifts

Critical Lifts

202 CARPENTER x x 439 COMBUSTION SERVICEMAN x x x

542 INSTRUMENTATION & CONTROL x x 576 POWERLINE TECHNICIAN x x x

596 MACHINIST x x 610 MAINT ELECTRICIAN x x 942 SHIFT ENGINEER CCNR x x 947 POWER PLANT UTILITY MAN x x

950 SHIFT OPTR CCNR x x 952 SMELTER UTIL SYSTEM OPT x x 964 WELDER FITTER x x 971 WINDER x x 976 MILLWRIGHT x x x

978 HD EQUIP TECHNICIAN x x


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6.0 VALE RIGGING TRAINING

6.1. LEVEL I – RIGGING TRAINING Objective: This training session is designed to provide a Vale employee with information about the selection, inspection and application of basic rigging hardware/equipment required to safely rig a load for a standard lift where the load weight, center of gravity, and rigging configuration is provided (in job procedure or job instruction) or known through on-the-job training and experience. Safe operating practices and risk management are stressed throughout the session. Delivery Method: Computer Based Training (CBT). Training on plant-specific standard lifts, procedures, processes, work instructions or lift equipment is NOT provided in this training. Duration: ~ 2-3 hours Topics covered include:

categorizing a lift: standard, non-standard and critical

risk assessment and risk assessment tools i.e. SLAM, JHA

guarding against related rigging hazards

determining basic rigging requirements for a load for a standard lift

inspecting and safely using slings and attachments, hitch configurations (vertical, choker, basket, multiple bridle legs), hitch points, lift charts, working load limits (WLL) and load angles

conducting pre-use visual inspections of rigging equipment and attachments before use

using international hand signals and communications

understanding safe practices required to execute a lift from start to finish

understanding Vale’s Golden Rule #5, current legislative regulations and standards related to lifting and mechanical handling activities

After Level I training, the worker shall be supervised until they are deemed to be competent to perform the standard lift rigging expected in their routine job duties without direct supervision. Level I training can be re-taken at any time as reinforcement of the concepts within this training module, or if a refresher is required.


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6.2. LEVEL II – RIGGING TRAINING Objective: This training session is designed to provide a Vale employee with training on the selection, inspection and application of rigging hardware/equipment required to safely rig a load for a standard or non-standard lift. In addition, training is provided on the creation of a lift plan for a non-standard lift. Safe operating practices and risk management are stressed throughout the session. Delivery Method: In-class training facilitated by Learning and Development includes hands-on training where participants will identify risks, develop a rigging plan specifying appropriate calculations, slings and attachments required to rig a load. Participants will experience a lift activity from start to finish. Any lift equipment or devices used in the demonstration of the full lift activity is operated by a trained, qualified and authorized person. Training on the operation of lift equipment/devices is NOT provided in this training. This session may be delivered by the Learning and Development Department instructor in conjunction with plant specific lift equipment/device training. Contact your Learning and Development Department resource person for more details. Duration: 1 Day Topics covered include all Level I topics plus the following:

conducting a formal risk assessment and developing a lift plan for a non-standard lift activity

determining load weight and center of gravity, using trade calculation or given documentation

calculating load angle factors, rigging capacities, and load integrity

identifying lift and hitch points

determining and selecting the appropriate slings and attachments, hitch configurations (vertical, choker, basket, multiple bridle legs), hitch points, lift charts, working load limits (WLL) load angles for the lift

performing pre-use inspection of rigging, rigging load, and lift and hitch points


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6.3. LEVEL III – RIGGING TRAINING Objective: This session is designed to provide a Vale employee with training on the selection, inspection and application of advanced rigging hardware/equipment required to safely rig a load for standard, non-standard or critical lifts. In addition, training is provided on the creation of a lift plan for non-standard and critical lift activities. Safe operating practices and risk management are stressed throughout the session. Delivery Method: In-class, hands-on training where participants develop lift plans and execute a lift from start to finish using appropriate calculations, slings and attachments. The session is delivered by Cambrian College using Vale approved instructors and content. Any lift equipment or device used in this training is operated by trained, qualified and authorized person(s).

Duration: 3 Days

Topics covered include all Level I and II topics plus the following:

developing a written lift plan

determine and select the appropriate advanced level of slings and attachments, hitch configurations (vertical, choker, basket, multiple bridle legs), hitch points, lift charts, working load limits (WLL) load angles for the lift

perform pre-use inspection of rigging, rigging load, and lift and hitch points for all levels of lifts

identify, use and understand the safe operation of various hand operated chain hoists and hand operated lever hoists

identify and apply advanced knots

identify and be able to explain the differences in types of rigging hardware - their strengths and limitations

attach rigging to loads to provide support or prepare them for moving

attach pulleys and blocks to fixed overhead structures such as beams, using beam clamps and other associated hardware

identify, use and demonstrate safe use of support and cribbing, chocks or staging

understand safety practices to rig a load to be drifted, moved through a narrow opening or confined space, or be transferred using chainfalls and other equipment


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7.0 TRAINING RECORDS Training records will be maintained by Vale’s Learning and Development Department and available for review upon request. For details on training codes contact your L&D Representative. Those qualified through Occupational Trades Training will be credited at the level indicated in Section 5.2 of this document. It is the Supervisor’s responsibility to ensure employees conducting rigging have their qualification to rig recorded correctly in Vale’s training records.

7.1. REFRESHER TRAINING Any of the Level I, Level II or Level III Rigging Training modules may be re-taken as refresher training. Refresher training is not mandatory.

While refresher training is not mandatory, it is the responsibility of the Supervisor to ensure that any employee conducing a rigging activity is trained and competent to safely rig the load for the category of lift they being authorized to execute i.e. Standard, Non-Standard or Critical Lift. If deemed necessary, a Supervisor may require an employee previously qualified to rig (through Vale training or Occupational Trades Training) to complete any of the Level I, Level II or Level III Rigging Training modules as a refresher.


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8.0 APPENDICES APPENDIX A: Revision Notes and Approvals


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Appendix A: Revision Notes and Approvals The revision notes are a summary of the changes and may not necessarily be a complete list.

Rev Revision Notes

Last revised by: Dan Jeanveau, Alain Arsenault and Janet Herman

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 November 2, 2016 meeting and by the Safety Health Environment Executive Committee at its November 28, 2016 meeting.

Document Review & Approvals

Name and Positions

Dated

Document Owner

Dave Duczeminski, Manager Maintenance Engineering

Dec 20, 2016

On behalf of the Maintenance Managers Leadership Group Ontario Operations

Dave Duczeminski, Manager Maintenance Engineering (Mines) Glen O’Neil Maintenance Engineering (Surface)

Dec 20, 2016

Ontario Operations

Bruce Bichel, Manager Production Services and Support

January 3, 2016

Documents

TRAINING & DEVELOPMENT LIFTING AND MECHANICAL HANDLING ...extportal.vale.com/maint/Sud/pdf/MSPEC-70002.pdf · maintenance standard specification ontario operations title training