Lifting Appliance Standard Hobart Smelter

Transcription

1 Lifting Appliance Standard Hobart Smelter

2 1 Purpose To define the policy for Lifting Appliances for statutory compliance under the following Sections: - 8 SECTION A LIFTING APPLIANCE DESIGN PROCEDURE SECTION B IDENTIFICATION NUMBER ALLOCATION SECTION C - INSPECTION FREQUENCY SECTION D LIFTING APPLIANCE INSPECTION DETAILS SECTION E LIFTING APPLIANCE PAINTING, SIGNAGE AND TAGS SECTION F STATUTORY INSPECTION PROCESS FOR COMPETENT PERSONS SECTION G GENERAL INFORMATION SECTION H RECOMMENDATIONS FOR INSPECTIONS Scope Of The Document This procedure applies to the following equipment used at the Hobart Smelter: - 3 Exclusion 1. Proprietary lifting Appliances (includes ropes, chains, slings, etc ) 2. Non-proprietary lifting Appliances 3. Monorails 4. Fixed Lifting Points 5. Fall Protection Anchor Points 6. Portable Ladders 7. Shackles and Eye Bolts This policy does not cover Fall Protection Equipment such as Lanyards, Harness and Decent Devices. Refer to Procedure HP for these details. This Policy does not cover the Electrolysis Lifting Racks used by Operating personnel in the Cell House, including 15 Point Lifters and the like. These are serviced and inspected as per Service Contract ZC Reference Material Regulatory Standards The following Australian Standards were referenced in assisting with this procedure: - AS1138 Thimbles for use with wire ropes or fibre (natural or synthetic) rope AS Flat synthetic-webbing slings Care and use AS1380 Fibre rope slings (of natural or synthetic rope) NOTE: Fibre rope slings are not to be used anywhere on a Mine Site AS1418.Parts 1 to 12 - SAA Crane Code

3 AS1438 Wire coil flat slings AS Wire-rope slings Product specification AS Wire-rope slings Care and use AS Portable Ladders Selection, safe use and care AS Industrial fall-arrest systems and devices Harnesses and ancillary equipment AS Industrial fall-arrest systems and devices Selection, use and maintenance AS2076 Wire rope grips AS2089 Sheave blocks for lifting purposes AS2317 Collared Eyebolts AS2318 Swivels for lifting purposes AS2319 Rigging screws and turnbuckles AS2321 Short link chain for lifting purposes (uncalibrated) AS2549 Cranes glossary of terms AS Cranes, hoists and winches Safe use, General requirements AS2740 Wedge type sockets AS2741 Shackles AS Steel wire rope Use, operation and maintenance AS3569 Steel wire ropes AS Chain slings Grade T Product specification AS Chain slings Grade T Care and use AS3990 Steelwork for engineering applications AS4100 Steel Structures AS Roundslings Synthetic fibre Care and use AS4991 Lifting devices Nyrstar Hobart Procedures and References HP Fall Protection Equipment and Inspections HP Protective Coating Specification HP Lifting Appliance Notation on drawings Work Place Health & Safety Regulations Letter from Tasmania Development Resources dated August 15, 1989, titled "Monorail Lifting Beams".

4 5 Definitions Competent Person A person having practical knowledge and relevant experience, sufficient to enable that person to detect and evaluate any defects and weaknesses that may affect the intended performance of the appliance. Lifting Appliances Are defined as stationary and travelling cranes, hoists, winches, monorails, davits, fixed lifting points and all special appliances provided for materials, cargo, personnel or equipment lifting purposes including, but not limited to, spreaders, lifting frames, pallet lifters, manbaskets, beam clamps and non-proprietary equipment or tackle. Proprietary Lifting Appliances or Tackle - Includes, but is not limited to, chain blocks, beam runners, pull lifts, hand winches, jacks, wire rope and synthetic fibre slings, chains, shackles, hooks and rings that are obtainable on an off-the-shelf basis. In application, a number of individual lifting appliances may be linked in series to form a 'lifting system', an example being: 1) Support Structure e.g. a beam 2) Fixed Lifting Point e.g. a lug attached to the beam 3) Lifting Machine e.g. an electric hoist suspended from the lifting point 4) Lifting Appliance e.g. a specially designed device to attach the load to be lifted to the lifting machine 5) Lifting Attachment e.g. a permanent part of the load to be lifted to which the lifting Appliance is attached In the above system, each of the five individual components (appliances) would be subjected to design approval in accordance with this Procedure. When an item of proprietary lifting equipment is to be permanently installed directly on an existing structure, or requires the manufacture of a special mounting, for example the installation of a hand winch for the purpose of raising a tank lid, the structure, special mounting and method of attachment are to be subjected to design approval in accordance with this Procedure. Non-Proprietary Lifting Appliances Appliances that are engineered, designed and manufactured for a specific application, e.g. cadmium spreader bar. Ladders - includes Timber, Aluminium and Fibreglass Reinforced types (FRP) WST Workplace Safe Tasmania WLL - Working load limit - The maximum load that can be applied to the Appliance. NOTE: The WLL may be changed for the particular conditions of use or the particular Appliance configuration in use (ref AS4991). SWL Safe Working Load - is commonly understood to be that load which a given lifting Appliance or lifting arrangement can safely lift, suspend or lower. This term is no longer used because of legal implications and has been replaced by WLL for Lifting Appliances (ref AS4991). SAP Nyrstar Business System Identification Number - a unique four-digit number Nyrstar - Nyrstar Hobart Pty Limited, ABN DMS Document Management System in SAP

5 Area - A specific part of the Nyrstar site, usually smaller than the organisational Department HOME.HO database Next Number Generation Database Monorail - A horizontally mounted beam or section onto which a trolley and lifting tackle may be fitted. The monorail functions as a support rail, which allows loads to be hoisted in the vertical axis. It also provides a means of transporting loads over defined areas in the horizontal axis. Fixed Lifting Point - A purpose-designed, rigid lug or eye, which is attached to a permanent structure. Appliances of this type are intended to be used with general lifting tackle for the support of loads in the vertical axis, during hoisting. Fall Protection Anchor Point - A purpose- designed, rigid lug or eye, which is attached to a permanent structure. Appliances of this type are intended to be used in conjunction with fall protection devices including safety harnesses and controlled descent / escape equipment. NOTE: Fall protection Anchor Points must not be used for general lifting. Davit / Jib - A cantilevered beam which may be rigid or able to be rotated through a horizontal arc. The means by which lifting tackle is attached to the lifting appliance generally defines the davit / jib as a monorail or as a fixed lifting point. (See details above). 6 Inspection Forms To assist in the inspection and record keeping specific Forms have been designed for each Appliance. These are located in the Document Management System (DMS). The Document reference numbers are listed in SECTION D Inspection Details Where External Service Providers are supplying this service, they must still provide inspection reports, which satisfy Australian Standard records and documentation requirements. 7 Responsibilities Maintenance Superintendent It is the responsibility of the Maintenance Superintendent that the inspection frequencies are in line with Australian Standard recommendations in the first instance and are also suitable for the usage rate and environmental conditions experienced at Nyrstar Hobart. Maintenance Planner It is the responsibility of the Maintenance Planner to ensure that the Statutory PM s are in SAP and are scheduled in accordance with the frequencies defined in this policy. Team Leader / Contract Coordinator It is the responsibility of the Team Leader / Contract Coordinator to ensure that these Appliances are inspected by a competent person in line with the frequencies defined in this policy and to maintain records in accordance with relevant Australian Standards. Operations and Maintenance Personnel It is the responsibility of the Operations and Maintenance Personnel to make available those Appliances when they are required for inspections.

6 Appliance Operator The Supervisor in charge of works shall ensure that all personnel involved in the works are properly trained in the use of the lifting gear to be used, and understand the importance of complying with correct use. The Supervisor in charge of works shall ensure that personnel using the lifting gear are holders of any license or certificate required for the operation of the gear in use, according to state legislation or standards applicable to that workplace. The person in charge of the lift (Rigger or Dogman) shall ensure that correct lifting gear is selected for the lift. The person in charge of the lift (Rigger or Dogman) shall ensure that lifting gear is not used for any purpose other than that for which it was intended and that lifting gear is not used in any operation, which would cause the safe working capacity of the gear to be exceeded or otherwise compromised. The person in charge of the lift (Rigger or Dogman) shall ensure that they are aware of the limitations of the gear, including the safe working capacity and any reduction of this due to the circumstances of the lift. Personnel must also be trained in the current work practices and procedures in the safe use of any hazardous substances used during the course of the work. The person in charge of the lift (Rigger or Dogman) shall ensure that all the lifting gear to be used: Is inspected daily prior to use and immediately after use and any defects found are reported immediately by the user to the equipment owner and the appropriate Nyrstar personnel. Any defective equipment is tagged with the appropriate Out of Service tag and set aside for repair by a suitably qualified person, or destroyed. Is clearly marked with the working load limit in tonnes (t) or kilograms (kg). Is inspected and certificated as per legislation requirements, regulations or standards applicable at NH. Equipment with reported defects shall not be returned to service unless satisfied that the defect has been rectified in accordance with the appropriate Australian Standard. Slings and lifting gear shall be included as an item for inspection during periodic safety audits. 8 Section A Lifting Appliance Design Procedure 8.1 Introduction It is a requirement of the Work Safe Tasmania (WST) that the design and method of construction of all lifting appliances, other than proprietary equipment or tackle, must be: a) Approved by an appropriately qualified Engineer before the appliance is manufactured and b) Tested and certified before being placed in service. 8.2 General Requirements Every item of plant or equipment that requires regular handling by mechanical means (e.g. rope blocks; chain blocks; hoists; cranes; mobile cranes; etc.) shall be provided with lifting lugs, lifting eyes, or other appropriate lifting attachments. Where necessary special spreaders, beams, frames, etc., shall be designed and supplied to facilitate easy attachment of the load to the lifting Appliance. All lifting appliances are to be designed and constructed in accordance with the appropriate Australian Standards.

7 All lifting appliances are to be designed by an experienced, qualified Engineer. Working Load Limits (WLL) for specifically designated structures are to be shown on the appropriate arrangement drawing(s) enclosed in a rectangle, as in the following examples. Working Load Limit 3 t Working Load Limit 860 kg For comments on Working Load Limit (WLL) see Clause 8.8 Working load limits of less than 1000 kg are to be shown in kilograms to the nearest whole kg. Working load limits of 1000 kg or more are to be shown in tonnes. Proof test loads are to be shown on the appropriate arrangement drawings. Each lifting appliance is to be distinguished by being finish painted Golden Yellow, Code Y14 to AS 2700 in accordance with Section E. Proprietary equipment or tackle can be a different colour, if their coating system is suitable for the local conditions of service. Working load limit signs are to be painted on or affixed to lifting appliances, in accordance with Section B. Each lifting appliance is to be allocated an Identification Number in accordance with Section B. Multiple appliances of the same design are to have individual Identification Numbers, except in the case of fixed lifting points where two or more points are installed for the purpose of a single lifting process, in which case one Identification Number will suffice. 8.3 Requirements for Approval The following guidelines have been compiled by WST to assist in the preparation of submissions for approval of lifting and other critical appliances under the Workplace Health and Safety Act 1995 and Regulation Refer to Plant Registration Form PRF 1 (applications for registration of plant design) for pressure vessels, boilers, work-boxes, hoists etc. 8.4 Unusual Designs Where Standards do not adequately cover the designer's intentions then the design will need to be discussed with WST before proceeding to final design and submission preparation. 8.5 Submissions In order to obtain approval it is necessary to show that the lifting appliance is properly designed, built to design and safe to use. If WST approval is necessary (see Clause 8.9), the procedure normally has three stages. Approval in principle by Nyrstar, WST design approval and an inspection/load test (with deflection measurement). To obtain design approval by WST it is necessary to make a submission in sufficient detail to enable the reviewing officer to understand the appliance and the basis of its design. A submission is made up of three parts, a descriptive section, an illustrative section and an analytical section Descriptive Section The descriptive section should indicate where the lifting appliance is to be used, what the appliance is to be used for, how the appliance works and what (if any) special circumstances apply to the location or use of the appliance. This section would for most designs contain information on the control system. For complicated or extensive systems this information would be supported by drawings.

8 The reviewing officer will use the information contained in this section to obtain an overview of the proposal and to decide what special provisions of the Standards apply to the design. Control systems would be reviewed for conformity with Standards (AS 1418 and AS/NZS 3000 Electrical Installations) Illustrative Section The illustrative section must contain sufficient arrangement and section drawings to permit the design to be visualised by the reviewing officer. It is not necessary to provide a full set of fabrication and detail drawings. In general the only details required are those appertaining to areas of critical or unusual design. If more detail is required by WST it will be requested. The drawings supplied with an application must have been checked and signed off as approved by a suitably experienced, qualified Engineer before submission. The drawings are reviewed to check that access, maintenance, clearances, operator positioning and equipment marking is up to standard (AS 1418 sections 11, 12, 13 and 14; AS 1657) Analytical Section The analytical section of the submission must contain full details of the following: Derivation of the lifting appliance classification (AS 1418 section 2 and 7). Design loading and load combinations (AS 1418 section 4 and 7; AS 1170). Stress and deflection checks (AS 1418 section 5 and appendix J; AS 3990 (Int.)). Stability checks (AS 1418 section 6). Design or selection of any mechanism or standard lifting tackle (AS 1418 part 7 and "A Guide for Riggers", 8 th edition). 8.6 Design Approval Limitations Approval of the design by WST is given in writing and may contain conditions. Any conditions must be complied with. The act of approving a proposal does not constitute transference of responsibility for the design to the authorities. The responsibility for the design remains with the designer. 8.7 Inspection When the manufacture and installation of the lifting appliance is complete it may be inspected by WST to ensure that it has been properly designed, installed and commissioned and proof load testing and deflection measurement will be witnessed. With small appliances the job of inspection and load testing may be delegated by WST to a nominated responsible person. 8.8 Hints (And Things To Look Out For) The difference between WLL (Working Load Limit) and SWL (Safe Working Load) when using standard tackle. Refer to "A Guide for Riggers" for assistance. WLL usually applies to proprietary equipment. The de-rating effect of galvanising, particularly with high strength steels. The increased brake holding power required when designing appliances to handle hot or dangerous loads (AS 1418 section 7). The effective de-rating of the WLL of most hoists when handling hot or dangerous load (AS 1418 clause 7.6.8).

9 8.9 Grant of Dispensation from Approval Process On 17 June 1993, the Inspector of Mines (Mechanical) granted special dispensation that permits what was Pasminco Maintenance Services to approve designs for lifting appliances, without a submission to the Inspectorate, under certain conditions: This has been superseded by subsequent Workplace Heath and Safety legislation, (see below, Clause 8.10) offering a more general exemptions from submission 8.10 The Internal Requirements Of Nyrstar For Design Approval Follow All requirements that would be required for approval by WST must be followed, apart from the actual submission to them This includes the written design submission (see Clause 8.5) and the inspection requirements (see Clause 8.7) Persons appointed to this capacity by the Asset Manager can only give approval. These will normally be Senior Engineers within the Department No person can approve his or her own design Calculations and drawings bear the notation: 'The design of this appliance has been approved' Designed by: (Name of Engineer) Employer: Approved by: (Name of Nyrstar Hobart Engineer) Date: The SAP Function Location is to bear the notation at the component level - 'The design of this appliance has been approved' Designed by: (Name of Engineer) Employer: Approved by: (Name of Nyrstar Hobart Engineer) Date: 8.11 Role of Consultants and Contractors Work Initiation in respect to Lifting Appliances A Nyrstar Officer at Superintendent level or above must initiate all work. Any request for work by Consultants or Contractors that has not originated from Engineering Department must be either referred back to the initiator or be referred directly to the Asset Manager Approval All requirements including the written design submission and the inspection requirements that would be required for approval by WST must be followed, apart from the actual submission to the Inspectorate Design Submission Design submissions must be forwarded to WST under the signature of a Nyrstar Hobart Superintendent Communication with WST Nyrstar must submit all written communications to WST by Consultants, Contractors or Nyrstar Hobart regarding conceptual designs or design submissions,, under the signature of the Senior Project Engineer.

10 8.13 Proof Load Testing All lifting appliances approved in accordance with Clause 8.9 are to be proof load tested to the relevant design Standard or as otherwise determined by the designer and deflection is to be measured and recorded, if applicable. In the case of minor fixed lifting points WST has advised that no proof load is required and that welded attachments are to be inspected as required by AS 1554, category SP (Structural purpose). External Service Providers (for inspections) may wish to test the equipment to gain a bench mark for future inspection regimes. Following any repairs; o Non-proprietary lifting Appliances are to be repaired and proof test loaded in accordance with AS4991; 2004 Section 12. o Monorails are to be proof test loaded in accordance with AS Section 12 or as specified by the designer Alteration or Repair of Approved Appliances Should it become necessary to alter an existing approved lifting appliance to suit a change in duty, the design of the total system or componentry is to be checked by a suitably qualified Engineer and necessary modifications designed and carried out in accordance with the procedure specified. A modified appliance will normally retain its original equipment number and it is therefore necessary that the following notation be added to the SAP Function Location at the component level: 'This appliance has been modified under Project No. (XXXX) and the revised design is approved' Designed by: (Name of Engineer) Employer: Approved by: (Name of Nyrstar Hobart Engineer) Date: Should repair to an existing approved lifting appliance be required it must first be subjected to an assessment by the Maintenance Superintendent or Engineering Department s Senior Engineer to determine: What caused the failure or damage? What is the structural effect of the failure or damage? What measures will prevent a recurrence? What repair or modification is necessary? What procedures should apply to the repair or modification? Any modification resulting from the repair is to be dealt with in accordance with Clause If it becomes apparent to any Nyrstar employee that an approved lifting appliance has been damaged, repaired or modified, or that its duty has been changed, the matter is to be directed to the supervisor Proprietary or Special Equipment Lifting appliances in the form of proprietary equipment, or appliances supplied with an item of proprietary equipment as an aid to operation or maintenance, for which design approval is required, are the responsibility of the supplier or manufacturer and the Project Leader is to ensure that such approvals are

11 obtained by the supplier or manufacturer and that all relevant data is provided to the Nyrstar Asset Owner and Maintainer. This should be a pre-condition of order placement whenever possible. Note: However, that where a special item of equipment is to be sourced from a supplier or manufacturer and is to form part of a lifting system, WST has indicated that a submission for design approval should be a single submission for the total lifting system. As an example, in the case of a specially designed electric hoist to be installed on a monorail designed by Nyrstar Hobart, the submission for design approval should be for both the hoist and the monorail, and be submitted by a Maintenance Superintendent or Senior Engineer. Special precautions or actions may be required for proprietary or special equipment sourced by Nyrstar Hobart from outside Australia. When appraising proprietary equipment or proprietary packaged plant, such appraisal should include the features, fixtures, facilities or attachments offered for mechanical handling of integral parts that will require removal or handling during operation or maintenance Equipment Handling In the design or specification of plant or equipment, every item of the plant or equipment, whether installed or free-standing, that will require handling by mechanical means for operation or maintenance, is to be provided with lifting points or attachments suitable to the type of mechanical handling involved. Where necessary, special lifting lugs, beams, frames, spreaders or tackle may have to be designed and provided to facilitate mechanical handling Filing of Data All calculations, correspondence associated with Nyrstar Hobart approvals or WST approvals and other information or documentation pertaining to lifting appliances must be filed by the Project Leader in the appropriate Project File (electronic and hard copies) and the Design Office is to hold the originals. If electronic copies are supplied these are to be attached to the equipment in SAP Hoisting Rope Attention is drawn to Regulation 907 of the Mines Inspection Regulations 1991, which is reproduced below: (1) Before a hoisting rope is put into service on a crane, hoist, winch or lift: a. A copy of the maker's certificate; or b. A certificate from an approved testing station - must be obtained which sets out - c. The full constructional details of the rope; and d. The class of steel used in the rope; and e. The breaking strength of the rope. (2) A copy certificate or certificate referred to in sub regulation (1) must be produced to an inspector upon request. In order for Nyrstar Hobart to comply with Regulation 907, the Maintenance Superintendent in each Department is to ensure that the requirements of the Regulation are followed and is to retain and file the certification. 9 Section B Identification Number Allocation 9.1 Introduction This procedure explains the process to allocate a unique "Identification Number" to either a:

12 Monorail, Lifting Appliance, Fixed Lifting Point, or a Fall Protection Anchor Point, And record the details in the CMMS. Does NOT apply to proprietary designed and built lifting equipment and tackle (see Clause 9.2.2) Does NOT apply to temporary lifting points used for construction or erection purposes only. 9.2 Equipment Registers The following Equipment Numbers (TECH ID s) have been generically allocated for Lifting Appliances within the SAP Register under each areas Statutory Equipment (SE) listing: Area Tech I.D. B22## LIFT## FIX## FPA## LAD## WINCH## Application BEAMS - for monorails LIFTING - for Lifting Appliances FIXED - for Fixed Lifting Points ANCHORS - for Fall Protection Anchor Points LADDERS for portable ladders WINCHES for non powered winches Where ## denotes the area (refer to HY-779-M-00529) Examples: B2202 = Roast Monorails Lift02 = Roast Lifting Appliances Fix02 = Roast Fixed Lifting Points FPA02 = Roast Fall Protection Anchor Points, etc LAD02= Roast Portable Ladders Proprietary designed and built lifting equipment and tackle The identification of proprietary items in SAP will be by means of either: a. An individual Equipment Number (TECH ID) as found under the relevant areas General Lifting Equipment listing OR b. For smaller items or tackle a component number under the relevant areas Statutory Equipment Proprietary Lifting Appliances listing. (PROP##) c. Listed by the external inspection service provider s database and available to Nyrstar personnel Each Lifting Appliance is allocated a component number as a subset of the relevant Equipment Number (TECH ID s) and is called an "Identification Number" (ZZZZ). "BEAM No. ZZZZ" - for monorails

13 "DEVICE No. ZZZZ" - for Lifting Appliances or Identification Number Examples: - "POINT No. ZZZZ" - for Fixed Lifting Points or ANCHOR No. ZZZZ - for Fall Protection Anchor Points, then a hyphen followed by a short description. Beam No.0034-Press Pump Service: 0.5t Device No Tube Bundle Frame, No.6 Superheater S.W.L.: 12.0 t Point No No.5 FBR, D/R Side Furnace: 4.0t Anchor No Davey Escape Second Floor Main Office S.W.L.: 500 kg When an Identification Number is required, the next available number is allocated by the from the Equipment Number database (APMTeam database) and allocated to the Area Register. See table and examples in Clause Allocation Of Next Available Number Issuing Number prior to Design & Manufacture: Contact the Design Office Supervisor, who will supply the next appropriate number in the series, register the Lifting Appliance in the database stored in (HOME.HO) and then contact the Maintenance Planner who will enter into the Function Location Structure in SAP Completing Details after Design Approval: (Refer Section A - Lifting Appliance Design Procedure) Once design approval has been completed the design information has to be provided to the Maintenance Planner for entry into SAP Bill Of Materials (BOM) Items Long Text as per the format specified in Clause

14 10 Section C - Inspection Frequency 10.1 Introduction This Section explains the rational in determining the inspection frequencies adopted at the Hobart Smelter for Lifting Appliances. The following table is to be used as a reference guide where the relevant Australian Standard does not give sufficient detail as to the appropriate inspection frequency. WHEN READ IN CONJUNCTION WITH THE RELEVANT AUSTRALIAN STANDARD AND MANUFACTURERS RECOMMENDATION, THE LESSER INSPECTION INTERVAL SHALL APPLY Table used as a guide only Monthly inspections HIGH Frequency of Use MEDIUM LOW GOOD OK BAD / POOR Environmental Conditions 10.3 Table Definitions FREQUENCY OF USE ENVIRONMENTAL CONDITIONS LOW Monthly GOOD Workshop conditions MEDIUM Weekly OK Plant areas that are usually not subjected to contaminants that could degrade the Appliance integrity. HIGH Daily BAD Plant areas that regularly contain contaminants that could degrade the Appliance integrity.

15 10.4 Proprietary Lifting Equipment (excludes synthetic slings) In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? Yes AS not greater than 12 months and prior to use No AS4991 does not clearly specify a frequency 2. Is the equipment stored in a secure location away from damaging contaminates? Yes Equipment stored in secure/clean areas. 3. What is average usage of the equipment? Low Low Low Low Low Low Low Low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK OK OK Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - Proprietary Lifting Equipment Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid

16 10.5 Non Proprietary Lifting Equipment In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? Yes AS not greater than 12 months and prior to use No AS4991 does not clearly specify a frequency 2. Is the equipment stored in a secure location away from damaging contaminates? Yes Equipment stored in secure/clean areas. 3. What is average usage of the equipment? Low Low Low Low Low Low Low Low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK OK OK Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - Non Proprietary Lifting Equipment Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid

17 10.6 Synthetic slings In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? Yes AS Not greater than 3 months and prior to use Yes AS Not greater than 3 months and prior to use 2. Is the equipment stored in a secure location away from damaging contaminates? Yes Equipment stored in secure cabinets. 3. What is average usage of the equipment? Low Medium Medium Medium Low Low Low low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK OK OK Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - (as AS overrides the Matrix result ) Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid Synthetic Slings

18 10.7 Monorails In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? Yes AS Not greater than 2 years and later in life may reduce to 12 or 6 months. 2. Is the equipment located in a secure location away from damaging contaminates? Yes for Monorails located in a Workshop environment No for Monorails located in Production Areas 3. What is average usage of the equipment? Low Low Medium Medium Low Low Low Low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK Good Good Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - dependant on location i.e. Workshop environment, Pump Rooms and similar = 24 months, Production environment = 12 months Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid Monorails 12/24 12/ /24 12/

19 10.8 Fixed Lifting Points In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? No AS4991 does not specify an inspection frequency. 2. Is the equipment located in a secure location away from damaging contaminates? Yes protective coatings applied 3. What is average usage of the equipment? Low Low Low Medium Low Low Nil Low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK Good Good Good Good Nil Good 5. What is inspection period as per Inspection Frequency Matrix Nil 12 Therefore, Inspection Frequency is: - Fixed Lifting Points Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid

20 10.9 Portable Ladders In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? Yes AS When purchased, put into service, before each use, after mishaps, and periodically. 2. Is the equipment located in a secure location away from damaging contaminates? Yes Ladders stored in a good environment 3. What is average usage of the equipment? Medium Low Medium Medium Medium Medium Low low 4. What is the severity of the typical operating conditions for this type of equipment? Good Good Good Good Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid Portable Ladders

21 10.10 Shackles and Eyebolts In order to come to a reasonable conclusion the following criteria were considered: - 1. Does the relevant Australian Standard recommend an inspection frequency? No AS2741 Shackles, Before each use. No AS2317 Collard Eyebolts Before each use. 2. Is the equipment located in a secure location away from damaging contaminates? Yes they are stored in a good environment 3. What is the average usage of the equipment? Medium Medium Medium Medium Medium Medium Low Low 4. What is the severity of the typical operating conditions for this type of equipment? OK OK Good Good Good Good Good Good 5. What is inspection period as per Inspection Frequency Matrix Therefore, Inspection Frequency is: - (as AS2741 & AS2317 overrides the Matrix result ) Wharf Roast Leach Electrolysis Casting Site E/I S.I. Other Acid Shackles and Eyebolts Before Use Before Use Before Use Before Use Before Use Before Use Before Use Before Use NOTE: All shackles and eyebolts shall have the following information included in their manufacture: - 1. Manufacture s identification 2. Quality Grade, as M or 4, or S or 6 3. WLL 4. Identification marking to correlate the shackle to the test certificate They shall not have a tag attached, as it is impractical to keep the tag attached. Defective Shackles or Eyebolts shall be taken from service and destroyed.

22 11 Section D Lifting Appliance Inspection Details This Section provides details of the inspections required to satisfy Australian Standards and local policy for Lifting Appliances used at the Hobart Smelter Non Proprietary Lifting Appliances Inspected in accordance with: - AS 4991 Section 12 Testing and Verification Section 13 Markings Section 15 Inspection and Inspection Certificate HFA Monorails Inspected in accordance with: - AS Section 9 - Inspection and Maintenance and AS Section 12 - Inspection and commissioning and Inspection Certificate HFA Trolleys Inspected in accordance with: - AS 1418 Section 9 - Trolleys and Inspection Certificate HFA Drum (Non powered) Winches Inspected in accordance with: - AS 1418 Section 7 Manually Operated Drum Winches and Inspection Certificate HFA Flat Synthetic Slings Inspected in accordance with: - AS Section 9 Inspection Section 11 Discard Criteria and Inspection Certificate HFA Chain/Lever Blocks Inspected in accordance with: - AS Section 2 Manually Operated Chain Hoists and Inspection Certificate HFA Chain Slings, Grade T Inspected in accordance with: - AS Section 9 Inspection and Inspection Certificate HFA Collard Eyebolts Inspected in accordance with: - AS 2317 Section 7 Marking and Inspection Certificate HFA

23 11.9 Shackles Inspected in accordance with: - AS 2741 Section 7 Marking Appendix B Care and Use and Inspection Certificate HFA Round Synthetic Slings Inspected in accordance with: - AS Section 9 Inspection Section 11 Discard and Inspection Certificate HFA Portable Ladders Inspected in accordance with: - AS Section 3 Metal Ladders Section 4 reinforced Plastic Ladders Section 5 Timber Ladders an Inspection Certificate HFA Fixed Lifting Points Inspected in accordance with: - AS 4991 Section 12 Testing and Verification Section 13 Markings Section 15 Inspection and Inspection Certificate HFA

24 12 Section E Lifting Appliance Painting, Signage and Tags 12.1 Purpose To define the painting and signage requirements for Lifting Appliances To conform to statutory regulations and the WST's recommendations 12.2 Scope Clauses 12.3 and 12.4 specifically applies to: - Monorails - Non Proprietary Lifting Appliances - Fixed Lifting Points - Fall Protection Anchor Points and covers: - Paint system and colour - Working Load Limit signage Clause 11.5 applies to Proprietary Lifting Appliances 12.3 Painting Non Proprietary Lifting Appliances shall be painted as per Nyrstar s Engineering Standard Practices PCS0003 HP Y14 golden yellow to AS2700, paint system type dependant on location. Proprietary items can be a different colour. Eg Kone Crane s yellow, Pacific Hoists orange, etc Signage On Lifting Appliances W.L.L Working Load Limit to have W.L.L. painted on in black lettering 100mm high (minimum). - WLL of less than 1000 Kg to be shown in kilograms to the nearest whole kilogram. - WLL of 1000 Kg or more are to be shown in tonnes to a minimum of one decimal place. Change the above to suit where: - Lettering not possible at this size, make as large as possible. - Lettering inappropriate, then, by stamping, etching welding or tagging. - Access to lifting appliance can be from both sides, signs are required on both sides. - Monorail is long, therefore requiring signs at various points throughout it's length, at no less than one sign per 10m

25 12.5 Appliance Information Tags (Proprietary Appliances only) All Proprietary lifting Appliances are to have an information tag attached (Shackles and eyebolts are exempt) The Information tag shall have clearly displayed as a minimum the following: - o Item #: o Test #: o Next Test Due: mm/yyyy o Date of Last Test: dd/mm/yyyy o Location: o WLL: o Inspection Body: (Specialist Service Provider s business name) Identification number Beam No. for Monorails Device No. for Non proprietary Appliances Point No. for Fixed Lifting Points Anchor No. for Fall Protection Anchor Points to be painted on in black lettering 50mm high Change the above to suit where: - Lettering not possible at this size, make as large as possible. - Lettering inappropriate, then, by stamping, etching welding or tagging Additional signage for Fall Protection Anchor Points shall be provided on the permanent structure to which the anchor point is attached. Signage is not to be attached to the eye of the Fall Protection Anchor Point. The text of the signage shall be black with a yellow background and shall read as follows; CAUTION This Anchor Point has been provided for the attachment of personal fall protection equipment including harnesses and escape equipment The attachment of other forms of lifting devices to this Anchor Point is NOT PERMITTED The label or signage must be clearly legible; text and label size shall be of an appropriate size to suit the individual application.

26 13 Section F Statutory Inspection Process for Competent Persons 13.1 Purpose - To describe the Inspection Process for Lifting Appliances 14 Process Flow Chart Inspection Process Flowchart Performance Requirements Monorail and Trolley HFA Area Representative Actions * Schedules work at Planning meeting * Ensures checklists are available * Allocates resource Item Found No Noted on Checklist "Not Available for Inspection" Yes PM prompts inspection Inspector Actions Inspection performed and checklist completed with all comments and actions * Name of Inspector * Company * Date * Status eg. Riggers Number Portable Ladders HFA Non-Propriety Lifting Equipment HFA Propriety Lifting Equipment HFA Fixed Lifting Point HFA Area Representative Informed ASAP David and Jib HFA AR Locates Item or Agrees that Item No Longer on Site Yes Item Found Equipment Pass? Yes No No Noted on Checklist "Item No Longer On Site" Item(s) tagged and removed from service Area Representative generates a Maintenance Order, as appropriate Checklist returend to Area Representative * Repair or, * Replacement or, * Destroys, as appropriate Update Equipment report with action taken and Maintenance Order Number Record filed in Departmental Fiing System (referenced in Critical Records Register) Maintenance Order Closed

27 15 Section G General Information 15.1 Hooks The safety hook should be of the type of fitted with a self-closing latch to prevent the displacement of the sling or load from the hook during lifting operations. If this is not the case, and an open hook is to be used then it must be moused off to prevent the lifting equipment exiting the hook mouth Hooks should be tamped or marked to indicate the Working Load Limit of the hook Hooks are to be painted yellow Chains: Chains used as lifting gear shall have all links free of defects such as distortion; excessive wear at bearing points; cracks; pitting; nicks or gouges Chains should not be shortened for the purpose of lifting by any means other than by a device specifically designed for that purpose Chains should be clearly marked with the working load limit of the chain in tonnes (t) Chains should not be used in a manner that causes the working load limit to be exceeded or compromised Synthetic Slings Slings are covered by Statutory Requirements No slings made from natural fibre are to be used or brought on to the Plant Synthetic fibre slings made only from POLYPROPYLENE or POLYESTER are permitted for use at Hobart Smelter All flat or round synthetic webbing slings are to be manufactured in accordance with AS or AS Synthetic webbing slings with manufacture dates earlier than 1990 and not marked as conforming to AS , are not to be used or brought on to the Plant The preferred type of synthetic webbing sling is round and of monofilament configuration All commercially supplied slings are to be inspected, used, maintained, washed, stored and condemned in full accordance with the manufacturers recommendations for the NH environment, or AS , whichever imposes the higher standard All slings manufactured from flexible steel wire rope are to be proof load tested and marked with the working load limit, date of proof testing and a unique serial number It is not legal to use a manually spliced sling for lifting purposes All synthetic fibre slings are to be under the control of a licensed Rigger, Dogman or Contract Supervisor. This does not preclude use by other people but the Rigger, Dogman and Supervisor are responsible for ensuring that the slings are used properly and in appropriate locations.

28 Synthetic fibre slings are not to be used in demolition work A record of purchase or manufacture, testing, inspection, condition, maintenance and washing, together with the date and reason for condemn, is to be maintained for each sling and is to be retained for at least six months after the sling has been condemned Personnel using, controlling and inspecting synthetic fibre slings are to be trained and retrained as necessary Personnel using, controlling and inspecting synthetic fibre slings are to monitor the appropriateness in the NH environment of material of manufacture and report to their Nyrstar Representative any problems experienced Slings shall be checked daily, before and after any lift, by the user for defects such as cuts; holes; tears; frayed material; broken stitching; worn or distorted eyes and other fittings Slings shall be destroyed should any of the above defects be detected Slings shall be clearly marked with the safe working capacity in tonnes (t) or kilograms (kg) The safe working capacity is not to be exceeded or compromised Slings shall be protected from corners or other sharp edges of the load by means of suitable packing materials inserted between the sling and the load Slings shall be stored after use off the ground and away from oils, solvents and other potentially damaging chemicals Shackles and Collard Eyebolts Before use, shackles and collared eyebolts should be inspected to ensure the following apply; a. Markings are legible 1. Manufacture s identification 2. Quality Grade, as M or 4, or S or 6 3. WLL 4. Identification marking to correlate the shackle to the test certificate b. The pin is the correct type c. The threads of the pin and the body are undamaged d. The body and the pin are not distorted e. The body and the pin are not unduly worn f. The body and the pin are free from nicks, gouges, cracks and corrosion NOTE: They shall not have a tag attached, as it is impractical to keep the tag attached. Defective Shackles or Eyebolts shall be taken from service and destroyed.

29 15.5 Wire Ropes Wire ropes used as lifting gear shall be inspected daily, before and after any lift by the user for defects such as wear; corrosion; kinks; mechanical abuse; flattening; distortion of lifting eyes; correct splicing They shall be destroyed as lifting gear should any of the above defects be detected Wire ropes used as lifting gear shall be clearly marked with the safe working capacity in tonnes (t) or kilograms (kg) They are not be used in a manner, which causes the safe working capacity to be exceeded Wire ropes used, as lifting gear shall be protected from corners or other sharp edges of the load by means of suitable packing material placed between the rope and the load Wire ropes are to be discarded if, in any length of the rope equal to ten times the size of the diameter of the rope, the visible number of broken strands is greater than five percent of the total number of wires in the rope Other Lifting Gear Other lifting gear shall be clearly marked with the safe working capacity of the gear This gear is not be used in a manner, which causes the safe working capacity to be exceeded or compromised or be used for any purpose other than that for which it is specifically designed.

30 16 Section H Recommendations for Inspections 16.1 General A competent person as defined under Clause 5 shall carry out inspections Recommendation Table The following are recommendations of who may inspect the Appliances as defined in Clause 2. These persons can either be NH Employees or an External Service Provider. Note: Each Appliance should be visually inspected prior to use. Equipment Type Frequency of Inspection (months) 1st Option 2nd Option Proprietary 12 External Testing Agency N/A Non Proprietary 12 External Testing Agency N/A Synthetic Slings 3 May use in-house person for 3, 6 and 9-month inspections. Forward Inspection Certificate to External Testing Agency for filing and updating database. Each 12 months completed by: External Testing Agency Monorails 12/24 External Testing Agency N/A Fixed Lifting Points 12 External Testing Agency N/A Fall Protection Anchor Points 12 External Testing Agency N/A Portable Ladders 12 External Testing Agency May use in-house person when new ladders are purchased. Forward inspection Certificate to External Testing Agency for filing and updating database. Shackles and Eye Bolts Before each use Prior to use by competent person Each 12 months completed by: External Testing Agency