FATALITY PREVENTION

ELEMENT 2.15

LIFTING AND SUPPORTING LOADS

CONTENTS PAGE
1.0 Context...................................................................2

2.0 PURPOSE..............................................................2

3.0 SCOPE...................................................................2

4.0 ELEMENT REQUIREMENTS................................2

5.0 DEFINITIONS.........................................................6

6.0 ATTACHMENT 1....................................................7

Version Date Reason for Change

001 19Dec2002 Implementation

Safety Improvement Committee Kepala Teknik

19-12-02
Date: Date: 20-12-02

Signature: Signature:
Fatality Prevention Element

FPE 2.15 Lifting and Supporting Loads

1.0 Context
The raising, lowering and supporting of loads is frequently performed using a diverse range of lifting
machines and equipment. Irrespective of the activity, any task requiring mechanical assistance is
considered potentially hazardous. It is therefore essential risk controls are established to prevent
situations arising that have the potential to result in fatal injuries.

2.0 Purpose
To detail the requirements to manage the design, maintenance, selection, and operation of lifting
machines, equipment and support stands such that loads can be lifted and/or supported in a safe
manner.

3.0 Scope
This standard applies to lifting machines, equipment, and support stands, owned and operated by KPC
or its contractors, which are used on KPC mining and infrastructure leases.

4.0 Element Requirements Accountability

4.1 Hazard Identification, Risk Assessment and Control

All lifting machines must be subject to a risk assessment in order to determine General Manager
requirements for:
 skills required to operate / use each type of lifting machine safely
 safety devices (limit switches / visual / audible warning systems, emergency
stop controls)
 signage and demarcation required
 operating environment (working near powerlines, ground conditions).
Changes to safe work procedures related to lifting activities or modification to lifting General Manager
machines or equipment must be in accordance with Prima Nirbhaya 5.43 Change
Management.
Any risk identified as having a potential to cause a fatal incident must be controlled General Manager
before the lifting of any loads is authorised.
A Job Safety Analysis (JSA) must be completed prior to work being conducted with Department
lifting machines or equipment used in the following situations: Superintendents
 people are required to work with the load during movements (guiding loads
in and out of restricted areas)
 non-routine task or lifting task being performed for the first time
 environmental hazards are present, (power lines, physical barriers, ground
conditions, etc)

4.2 Selection, Training, Competency and Authorisation

All personnel conducting risk assessments or JSA’s on lifting machines, equipment, General Manager
support stands, or their operation must:
 possess the skills and/or knowledge to operate/use the equipment
 hold the relevant KIMPER where applicable
 be assessed as competent to perform the JSA or the risk assessment

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FPE 2.15 Lifting and Supporting Loads

The training and competency assessment systems shall ensure: General Manager
 competency standards for personnel required to: HRD
 operate lifting machines, equipment, cranes, and attachments
 direct crane movement and overhead loads
 slinging and rigging of loads
 inspect lifting machines and equipment
 maintain lifting machines and equipment
 training and formal competency assessments for the above personnel
 the recording of all training undertaken and results of competency
assessments
 where required, the re-assessments of competencies shall be defined

4.3 Communication and Awareness

Changes to lifting machines or equipment, or lifting operations must be: Department
Managers
 documented and/or documents updated
 communicated to personnel who maybe affected

A load chart must be displayed in each mobile crane in a position visible to the Department
operator. Managers
Charts showing the sling size, load capacity and slinging arrangements must be Department
displayed in work and storage areas. Managers
Awareness information and/or instruction must be provided on a regular basis to Department
personnel who operate lifting machines or use lifting equipment, and must include Superintendents
topics on:
 safety requirements related to operating conditions (load limits, work area
preparation, power lines, wind speed)
 specific skills and or procedures (hand signals, lifting procedure)
Standard hand signals must be used when verbal communication between the Department
operator of a lifting machine and the signaller is impossible. The lifting machine Superintendents
operator shall only be directed by one person (signaller/ dogman).
The Safe Working Load (SWL) shall be prominently displayed and maintained on all Department
lifting machines, equipment, and support stands. Superintendents

4.4 Design, Purchase, Fabrication, Installation and Commissioning

Fabricated or custom built lifting equipment (including man-cages) and support General Manager
stands must be supplied with engineering calculations and drawings, checked and
certified by a qualified engineer, which demonstrate it can support the rated SWL.
Purchase and commissioning specifications for all lifting machines or equipment Procurement
must include the requirement for: Manager
 safe working load (SWL) displayed on equipment (mark load limits below
500kg in Kilograms, above 500kg in Tonnes)
 lifting machines must be supplied with operator manuals and load charts
 lifting Machines used to raise/lower people must comply with AS1735 and
AS2359
 Kep\men\555-Decree of Mines Article 154
All mobile lifting machines must follow the pre-commissioning process as required in Department
Prima Nirbhaya Fatality Prevention Element 2.18 Managers

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FPE 2.15 Lifting and Supporting Loads

4.5 Work Method and Condition Control
Personnel shall not be hoisted or lowered by a crane unless: Department
Superintendent
 the crane has a current inspection certificate, and
 an approved man-cage is used
The operation of lifting machine and equipment must address the following Department
requirements where relevant: Superintendent
 Safety requirements:
 a visual inspection must be performed prior to use
 lifting machines, equipment and support stands must be operated within the
range of its safe working load (SWL)
 a single operator must direct and control all lifting operations
 towing slings must not be used for lifting
 a safety latch must be fitted to each hook
 lifting equipment known or suspected to have been overloaded shall be
withdrawn from service and re-tested and/or examined
 Operational Requirements:
 where a KIMPER is required to either sling a load or operate a lifting machine
only those persons will be authorized to perform the task.
 access to areas where lifting operations are performed shall be restricted and
protection provided, or procedures developed, to ensure persons in the
vicinity are not subject to danger (eg. Loads shall not be lifted over persons)
 lifting equipment shall not be used in circumstances where its stability is
likely to be adversely affected unless appropriate precautions are taken to
ensure safe work
 adequate illumination must be provided during all lifting operations
 Legal Requirements:
 Kep\men\555-Decree of Mines Article 155,156,157
The positioning of support stands used on each type of vehicles & mobile Department
equipment must be formally identified through maintenance manuals or a safe work Superintendent
procedure to ensure the load is securely positioned and the support stands used are
suitable for the load.

4.6 Maintenance
A maintenance program for all lifting machines and equipment must include: General Manager
 current records of all lifting machines other than those identified in
attachment 1
 schedules for planned maintenance
 ensuring maintenance work is performed to manufactures specifications
 ensuring work is carried out by competent and authorised persons
 the maintaining of records for each lifting machine relating to the design,
manufacture, testing, examinations, repairs and modifications
Lifting equipment must be stored: Department
Superintendent
 on racks, hooks, or shelves, off the ground protected from contamination
 segregated by type or capacity to allow for ready identification
 away from direct sunlight to prevent UV damage to synthetic fibre slings

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4.7 Emergency Preparedness
Each overhead crane must be provided with appropriately positioned and demarked Department
crane isolation switches. Manager

4.8 Monitoring, Inspections and Audits

Annual audits must be performed to verify the quality and effectiveness of the General Manager
requirements set out in this standard. As a minimum this will include:
 schedules for audits
 audit verification of:
 quality of the risk assessments / JSA’s performed
 quality of the maintenance program
 compliance to training, competency, and awareness requirements
 compliance to design, purchase and commissioning requirements
 communication and reporting requirements
The inspection process for all lifting machines and equipment must include: Department
Managers
 a register of all lifting machines and equipment (machines and equipment
that do not need to be recorded on a register are detailed in Attachment 1)
 Inspection and testing of cranes will be performed as per Kep\men\555-Decree
of Mines Article 158 sub article (5)
“Every crane and item of lifting tackle at a mine shall be thoroughly examined
and tested to prove its safe working load at intervals not exceeding 12 months
by an authorized mechanical expert or test house appointed by the Technical
Mine Manager the name of which shall be recorded in the Mine Book”.

 checklists to prompt critical aspects to be inspected

 schedules for conducting inspections
 lifting machines formally inspected at monthly intervals
 lifting equipment shall be formally inspected at six-monthly intervals
 the recording of all inspections conducted .
 ensuring inspections are carried out by a competent person

Lifting machines and lifting equipment detailed in attachment 1 must be inspected Department
prior to use. Routine work place or equipment inspections shall include the Superintendent
inspection of these items.

The operator shall perform a pre-start check on all-lifting machines or equipment Department
prior to use. Superintendent

4.9 Reporting, Assessment and Corrective Actions

Hazards or defects identified with lifting machines or equipment must be reported, General Manager
assessed, corrected, and include:
 actions required to stand down unsafe equipment
 the recording of actions taken to correct the hazard or defect
 recording of defects shall also address Kep\men\555-Decree of Mines
Article 158 (6)
Lifting equipment which is identified as being worn or damaged beyond repair shall Department
be destroyed and the lifting equipment register and record file amended accordingly Managers

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5.0 Definitions
Accountability The person designated to ensure that the assigned requirement is
implemented. This person is held liable and answerable to the level of
compliance against the stated requirement.
Authorised Permission granted by the relevant Manager or nominee to carry out specific
tasks.
Competent Person A person having a combination of training, education, experience, acquired
knowledge and skills enabling them with the capability to perform specified
tasks to a pre-determined quality which may be assessed against defined
criteria.
Contractor A firm or person employed under a contract to provide services to PT Kaltim
Prima Coal as distinct from a contract of employment.
Department Manager Is the person nominated by KPC as Manager under the organizational
structure, also the most senior position with a firm contracting work to KPC.
KIMPER Is a record that identifies that an individual has been assessed as competent
and is authorized to operate the specified equipment or perform a
designated activity.
Lifting Equipment Any equipment used to provide a connection between a lifting machine and
a load. Includes components such as shackles, slings, hooks, chains and
spreader beams .
Lifting Machine Is a machine or component which uses a mechanical advantage to raise,
lower or suspend a load. Lifting appliance include cranes, elevators/lifts, for
personnel and materials, forklift trucks, stacker trucks, mobile working
platforms, pulley blocks, runway beams with trolleys, hydraulic/hi-lift jacks,
and davits.
Material Handling Non motorized structures used to assist in the manual handling of products
devices and material, these include (adjustable tables and trolleys, jibs rated less
than 200kg, roller tables)
Must / Shall Are to be interpreted as mandatory.
Operational Experience Is a person with a minimum of three years experience relating to the
purchasing, inspecting or maintenance with the particular (or compatible /
equivalent type) of lifting machine or equipment.
Potential to cause a A hazard that has been identified, and, that if not properly controlled will
Fatality / Risk of a contribute to a fatal incident. This can be derived from previous fatal incident
fatality experience and /or having being identified by means of a risk assessment as
having a consequence for fatal injuries.
Purpose made lifting Lifting equipment not available as a standard or proprietary item, which is
equipment required to be designed and manufactured for a specific task or duty.
Risk Assessment A risk assessment is the estimation of the level of risk associated with an
identified hazard in order to determine the resources needed to control it.
Risk is measured in the terms of consequence and probability.
Safe Working Load The weight that the weakest part of the lifting machine can safely support or
the sum of the safe working loads of two or more machines installed on the
one crawl beam.
Support Stands Fabricated devices designed to support a load of greater than 500 kilograms
for a temporary period. (vehicle stands, equipment stands, axle stands)
Working Load Limit The maximum load which the lifting equipment is designed to raise, lower or
suspend under ideal conditions (the safe working load will usually be the
same as the working load limit but may be less).
UV Ultraviolet. (radiation)

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6.0 Attachment 1

1. Exempt from recording on a register.

The following items need to be inspected before use, the routine work place or equipment inspections shall
include inspection of such items to ensure they are maintained in a serviceable condition.

Note: only those items list below will not be required to be recorded on a register,

 Shackles with an SWL 15 ton  All fixed lifting lugs

Pallet jacks that raise loads to a height of less
 Eye-bolts with an SWL 15 ton  than 1 meter
 Hydraulic / pneumatic jacks with SWL 5 ton  Wire slings and chains with an SWL  2 ton
 Towing slings  Material handling devices with a SWL  100 kg

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