PNR-000189 – Cargo Handling

Systems – General

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Rev_00 08.29.22
Summary

Summar
▪ VPS – Elements of the PNR Implementation Process
▪ Scope and Applicability
▪ Bowtie Synthesis
▪ Main Standards and RAGAGEP
▪ Critical Controls
▪ Highlights and Requirements
▪ Examples of Deployment / Application of PNRs
▪ Developers (multipliers)

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 VPS – ELEMENTS OF THE PNR IMPLEMENTATION
PROCESS
4. Perception and Risk Management;
Risk Management Requirements (MUEs).
5. Health, Safety, Environment and Community
(HSEC);
SSMAC requirements for Critical Assets.
6. Projects and Construction;
Requirements for Critical Assets in Projects.
7. Operations;
Requirements for Operating Critical Assets.
8. Maintenance;
Requirements for Maintenance of Critical Assets.
9. Change Management;
Requirements for Changes in Critical Assets.
10. Systems and Technologies;
Systems and Technologies applied in Critical Assets.
11. Supplies and Services;
Supply requirements for Critical Assets.
12. Emergency Planning
Emergency preparedness and response plans to
address emergency situations for Critical Assets.
3 Ensure that the organizational structure is
1. Behaviors and Leadership Commitment;
People Management with an inclusive environment
reinforcing values, key behaviors and organizational
discipline.
2. People Management and Training ;
Technical Competence and Training Requirements
3. Organizational Design.
respected.
ASSET
MANAGEMENT
13. Strategy Deployment;
Identification, prioritization, communication and
deployment of goals according to the company's
strategy.
14. Routine Management;
Definition and standardization of indicators,
performance routine, visual management and
verification of standards.
15. Processes and Standardization;
PNRs preparation and publication and Asset
Management Portal.
16. Problem Solving and Continuous
Improvement;
Problem identification and resolution through the
Lessons Learned, Benchmarks and Technical
Committees.
17. Assessment of Management System and
Results.
Performance evaluation of PNRs through the
Check Process.
 ASSET
SCOPE AND APPLICABILITY MANAGEMENT

Mobile Cranes Overhead Cranes Gantry Cranes Industrial Elevators

EXCLUSIONS
APPLICABILITY
• Monorail hoist;
• Typical Mobile Crane • Lifting platform;
• Railway Mobile Crane; • Fork-lift;
• Truck mounted crane;
• Overhead Crane; • Tower crane;
• Gantry Crane; • Jib crane;
• Temporary construction elevator;
• Industrial Elevator. • Conventional elevators for buildings;
• Underground mine elevator (shafts);
• Cable-way Systems.
Operation

4 Project Supply
Construction and
Commissioning Operation Maintenance Decommissioning
Assembling
 ASSET
BOWTIE SYNTHESIS MANAGEMENT
Failure Modes Preventive Barriers Risk Scenarios Mitigating Barriers Consequences

Asset / Load collision Structural collapse

resulting in
“Dead Man” Switch for Mobile fatalities
Crane
Mobile Crane Outrigger
System
Insufficient soil bearing Mobile Crane Boom Slewing
capacity during Angle Indicator / Limiter Loss of structural stability in Tipping causing
Mobile Crane Inspection and structural damage and
outrigging mobile cranes
Maintenance Program fatalities

Mobile Crane Level Indicator Emergency response

Loss of control of mobile plan
Mobile Crane Overload
Control crane operation Mobile crane
emergency stop device
Structural overload
Mobile Crane Boom Lift movements Extensive and
Control irreversible
Wind Speed and Direction environmental impact
Monitoring in a Mobile Crane Loss of control of load on due to load
Mobile Crane Hoist Holding characteristics
mobile cranes
Brake
Audio Visual Signaling on
Overspeed Mobile Crane
Mobile crane hoisting travel
limits Fall of the load
resulting in
fatalities

Hoisting
5 system failure
 ASSET
BOWTIE SYNTHESIS MANAGEMENT
Failure Modes Preventive Barriers Risk Scenarios Mitigating Barriers Consequences

Asset/Load collision Structural collapse

resulting in
“Dead Man” Switch for fatalities
Overhead and Gantry Crane
Overhead and Gantry Crane
Asset’s improper Inspection and Maintenance
movement Program
Anti-collision system for Loss of structural
overhead or gantry cranes stability in overhead
Grounding / LPS of the and gantry cranes Emergency response
overhead or gantry crane plan
Extensive and
Power supply failure Overload Control of the Overhead or Gantry irreversible
Overhead or Gantry Crane Loss of control of overhead Crane emergency stop environmental impact
Horizontal movement control and gantry cranes device due to load
of the overhead or gantry horizontal movement Physical limits for characteristics
crane overhead or gantry
Control of the overhead or crane movement
Structural overload
gantry crane hoisting Loss of control of load in
movement overhead and gantry cranes
Monitoring Wind Speed and
Direction in Overhead and
Gantry Cranes
Overspeed Hoist holding brake for
overhead or gantry crane Fall of the load
Audio visual signaling of the resulting in
overhead or gantry crane fatalities
Anti-wind brake system of the
Hoisting
6 system failure overhead crane or gantry
crane
 ASSET
BOWTIE SYNTHESIS MANAGEMENT
Failure Modes Preventive Barriers Risk Scenarios Mitigating Barriers Consequences

Asset/Load collision

Asset’s improper Elevator inspection and

movement maintenance program
Elevator Fire Protection
System
Elevator overload control
Loss of structural stability
Protection against slack rope
Power supply failure
in the elevator
Elevator transport car
enclosure
Elevator overspeed protection
Structural overload Protection against improper
access to the elevator
Elevator limit switches
of the industrial elevator
Loss of elevator motion
control
Structural collapse
resulting in
Emergency response fatalities
plan
Elevator emergency
stop device
Physical limits for
elevator movement
Elevator emergency
communication system
Elevator failure
causing structural
damage and
fatalities

Overspeed

Car and counterweight

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derailment
 ASSET
MAIN STANDARDS AND RAGAGEP MANAGEMENT

Scope Base Standard

EN 13000:2010+A1:2014
Mobile Cranes
ASME B30.5:2021

EN 15011:2020
Overhead and Gantry Cranes
ASME B30.2:2016

ASME A17.1:2019
Industrial Elevators
ISO 8100-1:2019

ASME B30.10:2019
Hooks and below-the-hook accessories
ASME B30.20:2021

ISO 12480-1:1997
Lifting planning and operation
ASME P30.1:2019

RAGAGEP – Benchmarking carried out in Mining, Petrochemical and Oil & Gas industries, whose RAGAGEPs
were 8 used in constructing these standards, which made it possible to apply requirements of relevant
international standards in a practical and efficient way.
 ASSET
CRITICAL CONTROLS MANAGEMENT

The Critical Controls below apply to Mobile Cranes and are detailed on “One Pages” in
Appendix II of the standard.

1. Emergency response plan

2. Mobile crane emergency stop device
3. “Dead Man” Switch for Mobile Crane
4. Mobile Crane Outrigger System
5. Mobile Crane Boom Slewing Angle Indicator / Limiter
6. Mobile Crane Inspection and Maintenance Program
7. Mobile Crane Level Indicator
8. Mobile Crane Overload Control
9. Mobile Crane Boom Lift Control
10. Wind Speed and Direction Monitoring in a Mobile Crane
11. Mobile Crane Hoist Holding Brake
12. Audio Visual Signaling on Mobile Crane
13. Mobile crane hoisting travel limits

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 ASSET
CRITICAL CONTROLS MANAGEMENT

The Critical Controls below apply to Overhead and Gantry Cranes and are detailed on “One
Pages” in Appendix II of the standard.

1. Emergency response plan

2. Overhead or Gantry Crane emergency stop device
3. Physical limits for overhead or gantry crane movement
4. “Dead Man” Switch for Overhead and Gantry Crane
5. Overhead and Gantry Crane Inspection and Maintenance Program
6. Anti-collision system for overhead or gantry cranes
7. Grounding / LPS of the overhead or gantry crane
8. Overload Control of the Overhead or Gantry Crane
9. Horizontal movement control of the overhead or gantry crane
10. Control of the overhead or gantry crane hoisting movement
11. Monitoring Wind Speed and Direction in Overhead and Gantry Cranes
12. Hoist holding brake for overhead or gantry crane
13. Audio visual signaling of the overhead or gantry crane
14. Anti-wind brake system of the overhead crane or gantry crane

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 ASSET
CRITICAL CONTROLS MANAGEMENT

The Critical Controls below apply to Industrial Elevators and are detailed on “One Pages” in
Appendix II of the standard.

1. Emergency response plan

2. Elevator emergency stop device
3. Physical limits for elevator movement
4. Elevator emergency communication system
5. Elevator inspection and maintenance program
6. Elevator Fire Protection System
7. Elevator overload control
8. Protection against slack rope in the elevator
9. Elevator transport car enclosure
10. Elevator overspeed protection
11. Protection against improper access to the elevator
12. Elevator limit switches

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 ASSET
HIGHLIGHTS AND REQUIREMENTS MANAGEMENT

Below are some examples of requirements that can be found in the standard:

Design
 For all new cargo handling equipment to be acquired, a technical specification (TS) shall be prepared.
 The limiting and/or indicator devices described in subsections 6.2.2.5.1 to 6.2.2.5.5 apply to all mobile
cranes with a rated capacity of 1 000 kg or more, or net lifting moment above 40 000 Nm, due to loading.
These devices shall meet the criteria defined in section 4.2.6 of EN 13000.
Construction, Assembling and Comissioning
 In the commissioning phase, performance and safety device tests should be performed in accordance
with the Inspection and Test Plan. The minimum tests during commissioning are listed in sections 6.3.2.1
to 6.3.2.3.
Operation and Maintenance
 Motion and performance limiting devices must not be routinely used as an operational control.
 For existing assets that do not have manufacturer's maintenance instructions, the activities described in
APPENDIX V – ITPM – Maintenance Activities should be observed as a minimum reference.
Supplies and Services
 In addition to the commissioning requirements described in section 6.3.2, all the documentation
necessary for the safe operation of the equipment, its correct maintenance, as well as certificates of
quality,
12 tests and warranties should be provided.
EXAMPLES OF DEPLOYMENT / APPLICATION ASSET
MANAGEMENT
OF PNRS

Example: Limiting devices and/or indicators:

These are electronic and physical devices that monitor the operation of equipment and prevent commands that lead to an unsafe
condition.

As part of the PNR, the design, operation and maintenance documents will specify the way (“How”) to implement the following
requirements:

✓ Creation of a technical specification for the acquisition of cargo handling equipment, ensuring that such devices are supplied
and have the required performance.

✓ Use of the information provided by these devices for lifting planning and operation activities;

✓ Maintenance plan including calibration and inspection criteria and frequencies.

PNR requirements may have more or less technical detail, whatever is necessary to establish safe
operational conditions. Such requirements will be detailed in project documents, procedures and operation
13 plans for application of the Standard
 ASSET
DEVELOPERS (MULTIPLIERS) MANAGEMENT

The standards are prepared by a multidisciplinary Technical Committee, made up of

representatives from various areas of Vale and specialist companies, under the leadership of
the Asset Management Board.

Committee participants have an important role as multipliers of standards: facilitating the

process of technical standard implementation, supporting their application and
deployment, and clarifying the understood.

Check the last Appendix to the standard and find out who are the representatives of your
area.

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