Las Leyes del control oscuro y tenebroso

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analysis, test methods, or materials developed or selected by SELLER, and does not relieve
SELLER from full compliance with contractual obligation.
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Revise & Resubmit. Work may proceed
subject to incorporation of changes
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4
5
Revise & Resubmit. Work may NOT proceed
Review not required. Work may proceed
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Document Status: 1
Octavio Aravena
EM - Mechanical
25580-220
001
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10/17/2011
V1A
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Confidential and Proprietary
Property of
FLSmidth
For Confidential Use Only
Not for Circulation, Distribution or
Reproduction
Without Prior Permission in Writing
Copyright 2011
All Rights Reserved.

Installation, Operation, and
Maintenance Manual
Serial Order No.: CSP0000419-06 A Through F
For
Bechtel/Xstrata Copper
Antapaccay
District of Cuzco, Peru
Performance Associates International
Acting as Agent for FLSmidth
Tucson, AZ
Purchase Order No.: 25880-220-POA-MLGF-00001
FLSmidth Order No.: CSP0000419-06
Doc. No. CSP0000419-06

Installation, Operation, and Maintenance Manual
CSP0000419-06
Revision and Distribution Record Sheet
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may
not be duplicated, disclosed, or used without written consent from FLSmidth.
iv
Revision and Distribution Record Sheet
Dorr-Oliver®
30-m3
Third Cleaner Flotation Cells
Customer: Bechtel/Xstrata Copper
FLSM Contract No: CSP0000419-06
Main Parts List No: CSP0000419-06
Manual
Volume
Remarks Rev.
No.
By Transmittal
Date
Distribution: Hard Copy Electronic
Customer 3 3
Customer
Approval:
Date:
Refer to Appendix 5—Revision Detail, for details of the re-
visions listed on this page.

CSP0000419-06
Caution
v
Caution: Read This Manual Carefully
This manual covers various procedures, recommendations and other matters concerning the
erection, operation, maintenance and repair of the Dorr-Oliver flotation cell. It is not intended
and, therefore, should not be understood to address all situations that may occur during the
erection, operation, maintenance and/or repair of the equipment. Note as well that certain of
the information in this manual may become outdated over time or may become unclear or ap-
pear inapplicable in whole or in part because of changes to the equipment by the owner or
others, its state of repair, the characteristics of the feed, site conditions, and/or other vari-
ables over which FLSmidth has no control. If a situation arises that is not addressed in this
manual or if any part of this manual has become outdated, is unclear, or appears inapplicable,
and installation, operation, or maintenance personnel are uncertain how to proceed, contact
FLSmidth without delay for advice before proceeding with the affected work. FLSmidth accepts
no liability for any loss, damage or injury that may result from proceeding in such situations
without FLSmidth’s prior notice and advice.
This equipment must be operated and maintained only by trained operators and maintenance
personnel who have been thoroughly trained and/or schooled with respect to applicable
OSHA/MSHA regulations, generally accepted industrial safety practices and, safety procedures
stated in this manual. In addition, appropriate lock out/tag out procedures and a plant-specific
safety plan must be followed in addition to procedures stated in this manual.
FLSMIDTH, ITS AGENTS, REPRESENTATIVES AND EMPLOYEES ARE NEITHER RESPONSIBLE
NOR LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEM-
PLARY, PUNITIVE, OR OTHER DAMAGES ARISING OUT OF OR RELATING IN ANY WAY TO THIS
MANUAL AND/OR CONTENT OR TRANSLATION OR INFORMATION CONTAINED WITHIN THE
MANUAL.
All contents within this manual, including, but not limited to text, logos and images are the
property of FLSmidth. No portion of the materials on these pages may be reprinted or repub-
lished in any form without the express written permission of FLSmidth.
BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND AND
AGREE TO THE TERMS OF USE.
Reference may be made in this manual to international or
national standards, guides or other references. It is the
responsibility of the reader to obtain copies of and read all
such standards, guides and references in context with this
manual.

CSP0000419-06
Warranty
vi
Warranty Conditions
This manual is not part of the contract under which the equipment was sold, nor is it a sepa-
rate contract for the supply of goods or services. Refer to the contract documents under which
the equipment was sold for information on any warranties that FLSmidth may have given and
for all other rights, duties and obligations that the parties may have regarding the equipment.
Nothing in this manual states or otherwise provides any warranties (express or implied) con-
cerning the equipment. So there is no misunderstanding, FLSMIDTH DISCLAIMS ALL EXPRESS
WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE.

CSP0000419-06
Foreword
vii
Foreword
In keeping with the FLSmidth commitment to provide the latest technology and improvements
in its products, FLSmidth is also committed to providing the highest level of service and help-
ing you solve your process problems.
Accordingly, if FLSmidth can help in the operation of your flotation equipment, feel free to con-
tact us at (801) 871-7000 or fax (801) 871-7001. Also, if you have any suggestions or com-
ments that will help us serve you better, please forward them to us.
To ensure you receive the full benefits of proper installation, maintenance and operation of the
Dorr-Oliver flotation machines, we ask you to thoroughly read and familiarize yourself with the
instructions in this manual. Refer to the Table of Contents at the front of the manual.
The equipment, including the accessory equipment furnished but not built by FLSmidth, must
be stored, installed, operated, and maintained according to the manufacturer's instructions to
ensure warranty coverage.
The instructions in this manual are based on information available at the time of issue of this
manual. The right is reserved to make subsequent changes to the instructions without obliga-
tion to replace existing copies.
Documents, drawings, technical manuals and all other information contained in this manual,
provided in conjunction with the purchase of FLSmidth products and services, are the property
of FLSmidth and are confidential and may not be made public or copied.
FLSmidth will not furnish editable electronic copies of any data and/or drawings at any time.
FLSmidth accepts no liability whatsoever for unauthorized changes and/or alterations to the
data provided.
English is the governing language. When manuals are provided in both English and any lan-
guage other than English, THE NON-ENGLISH TRANSLATION IS PROVIDED ONLY AS A CON-
VENIENCE. FLSmidth shall not be liable for damages caused by errors in translation. The Eng-
lish translation will govern in case of minor discrepancies. In the event of major discrepancies,
notify your FLSmidth representative immediately. Refer to the contact list in this manual for
applicable addresses and telephone numbers.

CSP0000419-06
Table of Contents
viii
TABLE OF CONTENTS
1 General Information ........................................................................................... 1.1
Scope ................................................................................................................. 1.1
Design Basis ....................................................................................................... 1.1
Documentation ................................................................................................... 1.1
Definitions and Abbreviations ............................................................................. 1.1
Legend ............................................................................................................... 1.2
2 Design and Operating Principle........................................................................... 2.1
Description of a Flotation Cell ............................................................................. 2.1
Details on the Flotation Cells ................................................................................ 2.1
Operating Principle ............................................................................................. 2.2
Design and Operating Data................................................................................... 2.2
3 Safety Instructions............................................................................................. 3.1
General Notes..................................................................................................... 3.1
Introduction ....................................................................................................... 3.1
Marking of the Flotation Cell ................................................................................. 3.1
General Notes on Safety for the Flotation Cell ..................................................... 3.2
Design Requirements........................................................................................... 3.2
Design Recommendation...................................................................................... 3.2
Foreseen Hazards to Personnel ............................................................................. 3.2
Permission to Work ............................................................................................. 3.2
Scrap and Waste................................................................................................. 3.2
Harmful Media.................................................................................................... 3.2
Specific Safety Precautions Concerning Erection ................................................. 3.3
Transport and Pre-Assembly at Site....................................................................... 3.3
The Use of Lifting Lugs ........................................................................................ 3.3
Other Specific Erection Safety Concerns ................................................................. 3.3
Electrical Isolation............................................................................................... 3.3
Specific Safety Precautions Concerning Operation and Maintenance.................... 3.5
Completion of Erection or Maintenance Procedures................................................... 3.5
Isolation of Energy Sources .................................................................................. 3.5
Requirements for Work Inside the Flotation Cell ...................................................... 3.5
Area Safety Signs ............................................................................................... 3.6
Equipment Safety Signs (by FLSmidth) .................................................................. 3.6
Cleaning of Equipment and Building....................................................................... 3.6
Welding Near Combustible Materials ...................................................................... 3.7
Consumables and Discharge of Waste .................................................................... 3.7

CSP0000419-06
Table of Contents
ix
Safe Job Procedures ........................................................................................... 3.8
Lifting ............................................................................................................... 3.9
Confined Spaces ............................................................................................... 3.10
Hearing Protection ............................................................................................ 3.12
Hand Tools....................................................................................................... 3.13
Powered Hand Tools .......................................................................................... 3.16
Using Hammers and Bars in Close Quarters .......................................................... 3.17
High-Pressure Air.............................................................................................. 3.18
High-Pressure Water ......................................................................................... 3.19
High-Pressure Hydraulic Systems ........................................................................ 3.20
Overhead Cranes and Rigging Practices................................................................ 3.21
Using a Pedestal Crane ...................................................................................... 3.30
Wire Hoisting Rope............................................................................................ 3.32
Hydraulic Oil .................................................................................................... 3.37
Safety Showers and Eyewash Stations ................................................................. 3.39
4 Erection.............................................................................................................. 4.1
Special Tools Required........................................................................................ 4.1
Installation Completed in Accordance With Standards ........................................ 4.1
Modifications ...................................................................................................... 4.1
Receipt and Storage Instructions........................................................................ 4.2
Planning and Installation Procedures.................................................................. 4.5
The Task on a Step-by-Step Basis ....................................................................... 4.6
Introduction ....................................................................................................... 4.6
Component Installation Sequence and Installation ................................................... 4.7
Erection Documentation.................................................................................... 4.21
Quality Documentation ...................................................................................... 4.21
5 Operation ........................................................................................................... 5.1
The Functions of the Flotation Cell ...................................................................... 5.1
Operation ........................................................................................................... 5.2
Preoperational Inspection..................................................................................... 5.2
Start-Up ............................................................................................................ 5.3
Shutdown .......................................................................................................... 5.5
Consumables and Discharge of Waste ................................................................. 5.6
Operational Supervision...................................................................................... 5.7
Routine Inspection .............................................................................................. 5.7
Troubleshooting.................................................................................................. 5.8

CSP0000419-06
Table of Contents
x
6 Maintenance....................................................................................................... 6.1
Maintenance Safety ............................................................................................ 6.1
Safety Statement................................................................................................ 6.1
Personnel Safety Warnings ................................................................................... 6.1
Preventive Maintenance...................................................................................... 6.3
Introduction ....................................................................................................... 6.3
Inspection and Adjustment................................................................................... 6.4
Troubleshooting.................................................................................................. 6.9
Component Replacement and Repair................................................................. 6.17
Reinstallation of the Mechanism .......................................................................... 6.19
Turn-of-Nut Method........................................................................................... 6.22
Lubrication ....................................................................................................... 6.23
Lubrication Procedures....................................................................................... 6.23
Lubrication Schedule ......................................................................................... 6.26
7 Spare Parts......................................................................................................... 7.1
The Importance of Spare Parts ........................................................................... 7.1
Parts List ............................................................................................................ 7.1
Storage and/or Shelf Life.................................................................................... 7.1
8 Appendices
Appendix 1—Parts List
Appendix 2—Drawings and Lists
Appendix 3—Accessory Equipment
Appendix 4—Additional Supporting Information/Miscellaneous
Appendix 5—Revision Detail
Appendix 6—FLSmidth Contact List
Appendix 7—Mechanical Checklist Forms

CSP0000419-06
1 General Information
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
1.1
Scope
This flotation cell manual provides the end user with all of the required information for the in-
stallation, operation, and maintenance for this vital concentrator production equipment item.
Additionally, all associated drawings, spare parts lists, and subsupplier detailed information
are included in this manual.
Design Basis
Based on Xstrata’s Antapaccay mineral deposit and production requirements, these flotation
cells have been designed to accomplish the flotation for this project at significantly reduced
capital and operating costs over the life of the project.
The machines, which separate minerals based on their different abilities to adhere to air bub-
bles that pass through the ore slurry, are 30-m3
third cleaners Dorr-Oliver®
flotation cells pro-
vided by FLSmidth.
References to Standards
The flotation cells have been designed to meet all specifications and standards associated with
its use according to the standards applied by the appropriate regulatory authorities and
FLSmidth.
Local regulations—if more stringent—take priority over instructions manuals.
For dated references to any publication, subsequent amendments to or revisions of any of
these publications apply to this instruction only when incorporated in it by amendment or revi-
sion.
For undated references, the latest edition of the publication referred to applies.
Documentation
Although this IO&M manual is designed to be all-inclusive, it may need to reference other ma-
terial provided by the EPCM contractor or client that is important to the overall understanding
of this manual.
See Section 8, Appendices, for additional documentation where available.
Definitions and Abbreviations
See Section 8, Appendices, for a list of definitions and abbreviations.

CSP0000419-06
1.2
Legend
Mandatory!
This symbol appears in the instruction manual to in-
dicate dangers which, in the case of non-observance,
may cause fatal or serious injuries!
Attention!
This sign is shown in the instruction manual where specific
attention and caution is needed to avoid damage to or de-
struction of the equipment and/or parts of the installation.
This sign is shown in the instruction manual to provide
supplementary information not directly affecting safety or
damage to equipment.
Attention!
This sign is shown in the instruction manual to
provide information concerning possible im-
pact on the environment, actions required for
prevention, and proper response.

CSP0000419-06
2 Design and Operating Principle
2.1
Description of a Flotation Cell
Flotation is performed in cylindrical mechanically agitated cells or tanks. Mechanical cells use a
large mixer and diffuser mechanism at the bottom of the mixing tank to introduce air and pro-
vide mixing action. The flow rate and tank size are designed to give the minerals enough time
to be activated.
Details on the Flotation Cells
The Antapaccay project uses different sizes and configurations of flotation cells. This manual is
for the Dorr-Oliver®
30-m3
third cleaners flotation cells.
The flotation cell, consisting of the cylindrical tank and drive assembly, is the basic module of
the FLSmidth system. The cells are connected together and arranged in elevated steps for
gravity flow of the slurry.

CSP0000419-06
2.2
Operating Principle
Mineral froth flotation is the most important mineral processing technique available today. In
flotation, gas bubbles produced by the mechanical agitation of the mechanisms are used to
float the mineral particles, through adhesion, to the surface of the cells for recovery.
Froth flotation commences by comminution (that is, crushing and grinding), which is used to
increase the surface area of the ore for subsequent processing and break the rocks into the
desired mineral and gangue in a process known as liberation, which then has to be separated
from the desired mineral.
The ore is ground into a fine powder and mixed with water to form slurry. The desired mineral
is rendered hydrophobic (repelled by water) by the addition of a surfactant or collector chemi-
cal (the particular chemical depends on which mineral is being refined). This slurry (called the
pulp) of hydrophobic mineral-bearing ore and hydrophilic (attracted by water) gangue is then
introduced into a water bath which is aerated, creating bubbles. The hydrophobic grains of
mineral-bearing ore escape the water by attaching to the air bubbles, which rise to the sur-
face, forming a froth. The froth is removed and the concentrated mineral is further refined.
Basically, the adhesion of the small particles to the gas bubbles reduces the specific gravity of
the combined mineral-air particles so that the specific gravity of their association is less than
the specific gravity of the slurry, so the particles are induced to rise in the slurry.
For additional information, refer to Section 5, Operation, and to the mechanism assembly
drawing in Section 8, Appendices.
Design and Operating Data
Design Considerations
The FLSmidth Dorr-Oliver®
flotation machine is a unique design with a patented rotor-stator
that delivers intense mixing and aeration. Low-pressure air is pumped into the cell through the
upper bearing housing, hollow upper shaft, tubular lower shaft and rotor, and is uniformly dis-
tributed throughout the slurry, providing optimum air-particle contact.
The Dorr-Oliver rotor-stator keeps solids in circulation and disperses sufficient air as fine bub-
bles, while keeping power consumption low. The single-wall vortex-profile rotor pumps the
slurry from the tank bottom and discharges it along the upper part of the rotor.
Slurry flow is directed outward and upward by the stator. This maintains good solid suspension
and air dispersion within the cell. The rotor acts as a pump and maintains even coarse mate-
rial in uniform suspension. Its small size, avoidance of nonproductive turbulence and elimina-
tion of unnecessary baffling around the lower part minimize power consumption. Slurry circu-
lation and solids suspension in the lower circulation zone is enhanced, while the froth blanket
remains smooth and quiet.
The air pockets created during rotation on the trailing face of each blade provide a large
slurry-air interface. Effective air-slurry mixing in the entire turbulent zone intensifies collisions
of bubbles and mineral particles throughout the tank, as the bubbles rise to the froth blanket.
Lower peripheral speeds minimize wear and yield further power savings. The cylindrical tank
shape improves mixing and air distribution because all points on the tank periphery are equi-
distant from the rotor discharge.

CSP0000419-06
3 Safety Instructions Document 7500271a
3.1
3 Safety Instructions
General Notes
Introduction
The flotation cell must only be used under the intended technical circumstances as defined in
current instructions manuals.
It is a prerequisite for the safety that all relevant rules and regulations for the prevention of
accidents are held available at all times.
FLSmidth will not assume responsibility for any damage resulting from abuse or improper op-
eration or inadequate maintenance of the ball mill or resulting from its operation or mainte-
nance by unqualified personnel, including personnel who have not acquired the skills required
to operate or maintain the equipment on the basis of the directions provided in the technical
documentation. Basic rules regarding safety in and around a mineral processing plant are out-
lined in the safe job procedures section. Your plant safety policies take precedence over these
general safety procedures, which are provided for general information.
Operator safety—and the safety of others—depends on reasonable care and judgment in the
operation of mineral processing equipment.
A careful operator is good insurance against an accident.
Most accidents, no matter where they occur, are caused by failure to observe and follow sim-
ple fundamental rules or precautions. For this reason, most accidents can be prevented by
recognizing hazards and taking steps to avoid them before an accident occurs.
Regardless of the care used in the design and construction of this type of equipment, there are
conditions that cannot be completely safeguarded against without interfering with reasonable
accessibility and efficient operation. Warnings are included in this instruction manual to high-
light these conditions.
Marking of the Flotation Cell
Where appropriate, equipment should be marked according to the most recent version of the
ATEX Directive.

CSP0000419-06
3.2
General Notes on Safety for the Flotation Cell
Design Requirements
Mandatory!
Devices for switching off for the prevention of unex-
pected start-up shall be used (e.g., where, during
maintenance or trial run, a start up of the machine
may create a hazard). Devices must be provided for
disconnecting (isolating) electrical equipment to en-
able work to be carried out without any attendant
risk of electrical shock or burn.
Design Recommendation
Where appropriate, installation of a manual and lockable ball valve in compressed air piping to
the equipment is recommended.
Foreseen Hazards to Personnel
Basic rules regarding safety in and around a mineral processing plant are outlined in this man-
ual under Safe Job Procedures.
Permission to Work
It is the responsibility of the erection supervisor or maintenance supervisor to ensure that all
personnel involved have studied and fully understand:
• The permission given to perform work in the specific area.
• All relevant instructions concerning health and safety and the contents of this instructions
manual.
Scrap and Waste
Scrap and waste must be handled in accordance with site policies.
Harmful Media
The process media and the lubricants may cause danger to health. The material safety data
sheet (MSDS) informs any danger and precautions. These are found in the appendices.

CSP0000419-06
3.3
Specific Safety Precautions Concerning Erection
Attention!
Any erection activity must be carried out by skilled per-
sonnel and is subject to the supervision of authorized per-
sonnel. See Glossary of Terms in the appendices.
Mandatory!
The directions outlined in instruction manual 32031,
General Safety Regulations on Erection Site, must be
strictly observed at the site of erection.
Transport and Pre-Assembly at Site
Refer to Section 4, Erection.
The Use of Lifting Lugs
The individual parts supplied from the workshop will not be equipped with welded-on lifting
lugs. If lifting lugs still should appear, they cannot be considered suitable for erection lift. Dur-
ing handling and erection, the gate may be fitted with lifting lugs which correspond to the spe-
cific load and centre of gravity of the parts to be handled during the installation. Technical
documentation must be provided for lifting lugs fitted at the site of construction as defined by
the applicable rules.
Other Specific Erection Safety Concerns
Attention!
Check the suspension and working load of support system
before application of loads from the flotation cell.
Attention!
A final erection check must result in a release note to
commence test or operation of the equipment. See the
appendices.
Mandatory!
The fumes given off during welding and cutting can
be injurious to the operator's health. Some fumes,
such as those produced when working with zinc,
cadmium, and painted surfaces, can be toxic.
Electrical Isolation
Mandatory!
Be sure that the flotation cell and related equipment
are properly grounded before power is supplied.

CSP0000419-06
3.4
Electrical Supply
Mandatory!
Electrical supply to the flotation cell must be in-
stalled according to EN 60204-1. Improper installa-
tion entails safety risks.

CSP0000419-06
3.5
Specific Safety Precautions Concerning Operation and
Maintenance
Mandatory!
Any operational or maintenance activity must be
carried out by skilled persons and is subject to the
supervision of authorized personnel.
Completion of Erection or Maintenance Procedures
Attention!
Before any operation or test activity commences, an au-
thorized person (see Glossary of Terms) must declare that
erection or maintenance has been completed and that the
equipment has been released for operation or test.
Isolation of Energy Sources
Mandatory!
It is dangerous to perform test or maintenance ac-
tivities before it is ensured that it will be impossible
to restart the flotation cell or any adjacent equip-
ment in the process (e.g., locally or by means of a
remote control unit). Gravity force may constitute a
risk. It must be ensured that neither mechanical
components nor media may constitute a risk to any
person.
Refer to the shut down procedure in Section 5.
Attention!
Where appropriate, shut off the lockable ball valve in the
compressed air pipe to the equipment.
Requirements for Work Inside the Flotation Cell
Mandatory!
Media flow to or through the flotation cell consti-
tutes a risk to personnel working inside the flotation
cell. Ensure that no media rush to or through the cell
may occur. Gravity force may cause media rush. En-
sure a permit to work system for work inside the
cell. Allow cooling of the flotation cell before main-
tenance activity.

CSP0000419-06
3.6
Area Safety Signs
Safety signs should be installed to alert anyone entering dangerous areas. Several safety signs
may be required and located so they can be seen from any direction the equipment might be
approached.
Suggested text for these signs in appropriate language would be:
WARNING:
EXPOSED MOVING PARTS—KEEP AWAY
WARNING:
LOCK OUT POWER BEFORE
PERFORMING MAINTENANCE
If personnel working with this equipment cannot readily read or understand English, warning
signs on the equipment and procedures set forth in this manual must be translated and pro-
vided for their benefit in a language they understand. Multilingual signs may be needed.
Location of signs will depend upon the specific design and placement of the equipment. They
may be located above catwalks, for example, or affixed to walls adjacent to the equipment, or
on the equipment itself. Make sure these signs are visible to the operator during operation and
visible to persons approaching the area of the machine.
Equipment Safety Signs (by FLSmidth)
Safety and warning signs are shop-mounted to the equipment.
These signs must be kept clean and must not be covered up. Replace these signs if they are
damaged or deteriorated.
Cleaning of Equipment and Building
Mandatory!
Mechanical equipment, steel structures and surfaces
of compartments must be kept clean from dust,
scrap, and dirt. In particular, all kinds of combusti-
ble material constitute a risk of fire or dust explo-
sion.

CSP0000419-06
3.7
Welding Near Combustible Materials
Mandatory!
Follow all appropriate guidelines and regulations
when welding near combustible materials. Be sure
to have an extinguishing device readily available.
Consumables and Discharge of Waste
Mandatory!
Dangerous or unsafe consumables or discharge of
waste must be handled and disposed of according to
all appropriate guidelines and regulations

CSP0000419-06
3.8
Safe Job Procedures
To ensure employee safety, safe job procedures have been prepared for specific tasks. These
tasks can be handled safely if all personnel recognize potential hazards, develop safe work
habits, and follow the proper procedures.

CSP0000419-06
3.9
Lifting
Special Equipment Required
Work gloves
Introduction
You will be required to lift objects during your work. Whether lifting is part of your daily job or
only something you do occasionally, lifting an object incorrectly can cause serious harm, re-
gardless of your weight and physical condition. However, correctly following procedures (and
doing some stretching exercises to warm up your body and prepare it for physical activity) can
significantly reduce the risk of accidents.
Instructions
1. Clear the area of obstructions, litter, and tripping hazards.
2. Plan ahead and prepare the area where the object is to be placed.
3. Test the weight to be lifted. If it is too heavy, get help. A person is allowed to lift a
maximum of 22.67 kg (50 lbs).
4. Move close to the load.
5. Place one foot 203.2 mm to 304.8 mm (8 to 12 inches) ahead of the other.
6. Squat down close to the load by bending at your knees.
7. Keep your back straight and as vertical as possible.
8. Place your hands under or around the load, and get a good grip with your palms to
keep the load from slipping. (Remember: The palms are stronger than the fingers.)
9. Using your legs, lift gradually. Do not jerk or twist your body.
10. Keep the load close to your body.
11. Do not rotate your back. Turn your body by moving your feet.
12. Set the load down gradually by bending at your knees.
13. Keep your back straight when lowering the load.
14. Be especially careful when lifting in tight spaces; protect your fingers at all times.
15. Get help for bulky or heavy loads.

CSP0000419-06
3.10
Confined Spaces
Oxygen gas detector
Combustible gas detector
Air line respirator with egress unit (as directed)
Self-contained breathing apparatus (as directed)
Introduction
A confined space is any location so enclosed that natural ventilation may not reduce air con-
taminants to safe levels and where entry may result in injury due to any of the following:
• An atmosphere that may be flammable or explosive.
• Lack of oxygen required for breathing.
• Toxic materials that could result in injury, health impairment, or death if they contact the
body or are inhaled.
• General safety hazards such as steam, high-pressure gases or liquids, or other work-area
hazards that could result in serious injury.
Instructions
The supervisor who is immediately responsible for work in a confined space must do the fol-
lowing:
1. Inspect the area for hazards.
2. Test the confined space as follows:
2.1. Check the confined space for flammable or explosive potential.
2.2. Test the atmosphere for combustible gases by using a combustible-gas detec-
tor. No one may enter the space until the source of the combustible gas has
been isolated and the confined space is safely free of that gas.
Mandatory!
Never enter an enclosure that is an explosion haz-
ard.
2.3. Ensure that the confined space has adequate natural ventilation, and/or install
explosion-proof fans and ducts for air delivery. If the area is still oxygen-
deficient (less than 19.5 percent oxygen) after using positive ven-tilation, use
a self-contained breathing apparatus or air line respirator.
Mandatory!
Never use internal combustion engines inside en-
closed spaces.

CSP0000419-06
3.11
3. Check the confined space for toxic or corrosive materials. When toxic or corrosive ma-
terials that could result in injury by contact or inhalation are present, perform the fol-
lowing:
3.1. Empty the confined space and flush it with a generous amount of pressurized
water until safe limits for the hazardous materials are reached.
3.2. Welding, burning, or heating in a confined space may generate toxic fumes
and gases. Everyone in such a confined space must be protected by adequate
ventilation or an air line respirator with egress unit.
3.3. Those entering a confined space that contains corrosive materials must wear
eye protection and other appropriate protective equipment.
4. Check equipment to be used and general conditions of the space.
4.1. All entryways (such as gates, ducts, and piping) that may allow hazardous ma-
terials to enter the confined space must be disconnected or locked out accord-
ing to standard lockout procedures.
4.2. Equipment items (such as fans) in the confined space may be started by re-
mote commands. Deenergize and lock out these items according to standard
lockout procedures.
4.3. For those hazards that cannot be eliminated, adequate personal protective
equipment must be provided and used.
4.4. Verify that alarm devices indicating the presence of gas or oxygen deficiency
are in good condition.
4.5. Make available and ready for use all appropriate emergency equipment, in-
cluding at least two self-contained breathing units. Ensure that all workers in
the confined space have been trained to use the emergency equipment.
4.6. At least one person must be immediately available outside the confined space
to provide assistance if necessary.
4.7. In the case of a rescue attempt, self-contained breathing units must be used.
4.8. Prepare a rescue plan in the event of an emergency. Communicate the plan to
all workers in the confined space, and ensure that everyone fully understands
the plan.
4.9. All workers in confined spaces must wear safety harnesses equipped with life-
lines if deemed appropriate by management.
5. Determine that the area is safe, request a confined-space entry permit, and sign the
specific written authorization to work in the confined area.
6. Ensure that all employees understand entry procedures and how to use all emergency
equipment.

CSP0000419-06
3.12
Hearing Protection
Earplugs
Introduction
Noise is a deceptive hazard. Workers can be exposed to considerable amounts of it and not be
conscious that they may have suffered permanent injury. Noise intensity exceeding an aver-
age of 85 decibels over an 8-hour period can cause hearing loss. Noise also increases a
worker’s fatigue and stress level. Noise ultimately presents additional hazards when the
worker is unable to clearly hear instructions or warning signals.
Instructions
1. Know the types of hearing protection available in your area. The three basic types of
hearing protection are earplugs, canal caps, and earmuffs.
2. Select the hearing protection that is most comfortable and effective for you. Protection
that is uncomfortable is not likely to be worn as often as needed.
3. Always follow the manufacturer’s instructions for cleaning and storage of reusable ear
protection.
4. Be conscientious about using the protection at all times in posted areas and any time
there is exposure to noise.
Health Hazards
In extreme noise-exposure areas, earplugs and earmuffs are recommended. The selection and
wearing of adequate hearing protection is part of the company’s safety policy and should be
taken seriously by the employee.

CSP0000419-06
3.13
Hand Tools
None
Introduction
Hand tools that are in poor condition or misused are a major cause of accidents in the work-
place. Proper maintenance and necessary replacement of hand tools are critical to reducing
accidents and injuries. All workers must ensure that their tools are safe to use, in good repair,
adequate for the work, and free of defects.
Instructions
1. Workers must inspect their hand tools before use to ensure that they are in proper
working order. Damaged or defective tools must be reported to the supervisor and
must be repaired or removed from service.
2. Supervisors must inspect the tools of all workers at least twice a year to ensure that
tools are in proper working condition and meet appropriate guidelines. Inspection lists
must be prepared, inspections done, and records kept, according to maintenance
specifications.
3. Tools and jigs especially designed for a specific purpose should be checked by a quali-
fied person to ensure that there are no inherent or hidden safety hazards.
4. Proper and appropriate personal protective equipment must be worn when using all
tools.
5. All tools must be cleaned and properly stored after use. Each tool must have its own
storage area to prevent damage. This is particularly important with power tools.
6. Tools must not be used beyond their manufacturer’s designed capacity since such use
may create a personal hazard. Tools must be used solely for their intended purpose.
The designed capacity of tools must not be exceeded by unauthorized attachments.
7. Power drills, disc sanders, grinders, and both circular and chain saws (when used in
hand-held mode) must be operated with deadman controls that require constant hand
pressure.
8. Power tools must not be equipped with devices that lock onto the operating controls.
9. Do not use power tools with worn or damaged cords.
Power tools should be inspected annually to ensure they
are adequately grounded.
10. Face shields or goggles must be worn when operating a grinding wheel.
11. Power saws, grinders, and other power tools must have proper guards in place at all
times and must be properly grounded. Those with automatically adjusting guards must
be inspected for proper movement.
12. Power tools must be hoisted or lowered by hand line and never by the electrical cord
or hose.
13. All fuel-powered tools must be shut down while being refueled. Smoking is prohibited
during refueling operations. Other nearby sources of ignition, such as burning and
welding, also must be halted during refueling operations.

CSP0000419-06
3.14
14. Chisels, screwdrivers, and pointed tools should never be carried in a pocket. They
should be carried in a toolbox, cart, carrying belt, tool pouch, or in the hand with
points and cutting edges away from the body.
15. Inspect and check the following common hand tools:
15.1. Screwdrivers: Ensure that handles are smooth and clean and that bits are
sharp and square. A sharp square-edged bit will not slip as easily as a dull
rounded one and requires less pressure. When working around electrical-
current-bearing equipment, use an insulated screwdriver as a secondary pre-
caution.
15.2. Hammers: Ensure that handles are unbroken and clean and that the face of
the head is smooth and clean. Hammers are made in various types and sizes,
with varying degrees of hardness and different configurations for specific pur-
poses. Use the correct hammer for the correct purpose.
15.2.1. Common Nail Hammers: These are designed for driving common nails
by using the center of the hammer face. Nail hammers are made with
a curved, straight, or ripping claw.
15.2.2. Ballpeen Hammers: These are designed for striking chisels and
punches and for riveting, shaping, and straightening unhardened
metal.
15.2.3. Sledge Hammers: Sledge hammers are designed for general sledging
operations in striking wood, metal, concrete, or stone.
15.2.4. Riveting and Setting Hammers: These are designed for driving and
spreading unhardened rivets on sheet metal work, forming sharp cor-
ners, and closing and peening seams.
Consult manufacturers for specific needs in other types of hammers.
Mandatory!
Always wear safety glasses when using a hammer. A
hammer blow should always be struck squarely.
Avoid glancing blows.
15.3. Punches: Punches are designed to mark metal and other materials that are
softer than the point end, to drive and remove pins, and to align holes. Never
use a punch with a mushroomed struck face or with a dull, chipped, or de-
formed point. Any bent, cracked, or chipped punch must be removed from
service.
15.4. Chisels: Cold chisels have a cutting edge for cutting, shaping, and removing
metal softer than the cutting edge. Factors determining the selection of a cold
chisel are the material to be cut, the size and shape of the tool, and the depth
of the cut to be made. Ball chisels held by one person and struck by another
require the use of tongs or a chisel holder to guide the chisel.
15.5. Files: Ensure that tangs are protected by handles and that teeth are sharp and
clean. The correct way to hold a file is to grasp the handle firmly in one hand
and use the thumb and forefinger of the other to guide the point. Push the file
forward while bearing down on it. Release the pressure and bring the file back
to its original position. Never use a file without a smooth, crack-free handle.
Select the proper file for the work.

CSP0000419-06
3.15
15.6. Knives: Ensure that the handle is guarded and that the blade is sharp. The
cutting stroke should be away from the body. Avoid jerky motions. Keep
knives and other sharp hand tools separated from other tools. With the knife’s
sharp edge turned away from the hand, wipe the blade with a towel or cloth.
Do not substitute knives for can openers, screwdrivers, or ice picks.
15.7. Shovels: Keep shovel edges trimmed, and check handles for splinters. When
not in use, hang up shovels, stand them against walls, or keep them in racks
or boxes. The handles of shovels, spades, and similar tools must be made of
wood.
15.8. Wrenches (Spanners): Safe use of all wrenches requires that the user always
be alert and prepared for the possibility that the wrench may slip, the fastener
may suddenly turn free, or the wrench or fastener may break. The user must
always inspect the wrench for flaws.
15.8.1. Open-End Wrenches: Open-end wrenches have strong jaws and are
satisfactory for medium-duty turning.
15.8.2. Box and Socket Wrenches: These wrenches are necessary for a heavy
pull. Never overload the capacity of a wrench by using a pipe exten-
sion on the handle or by striking the handle with a hammer. For ex-
tremely tight screws and nuts, use a socket wrench, which is designed
especially for heavy-duty use. When possible, use penetrating oil to
loosen tight nuts.
15.8.3. Socket Wrenches: Socket wrenches should be kept clean of dirt and
grime inside the socket to ensure that the tool fits securely on the bolt
or nut.
15.8.4. Adjustable Wrenches: Adjustable wrenches are generally recom-
mended for light-duty work. Place the adjustable wrench on the nut
with the open jaws facing the user; wrenches should be pulled, not
pushed.
15.8.5. Pipe Wrenches: Both straight and chain pipe wrenches must have
sharp jaws and be kept clean to prevent their slipping. The handle of
every wrench is designed to be long enough for the maximum allow-
able safe pressure. Do not use handle extensions to gain extra turning
power unless the wrench is so designed. Never use a pipe wrench on
nuts or bolts.
Pliers may be used for gripping and cutting operations, but
they are not a substitute for a wrench.

CSP0000419-06
3.16
Powered Hand Tools
None
Introduction
Powered hand tools in poor condition or misused are a major cause of accidents in the work-
place. Proper maintenance of powered hand tools is critical to reducing accidents and injuries.
Everyone must ensure that his or her tools are safe to use, in good repair, adequate for the
job, and free of defects.
Instructions
1. All tools must be inspected before their use to ensure that they are in proper working
order. Damaged or defective tools must be repaired or removed from service.
2. Tools of all apprentices and tradespeople must be inspected by an authorized person
at least twice a year to ensure that tools are in proper working condition and meet re-
quirements. Inspection lists must be prepared, inspections must be made, and records
must be kept under the direction of the maintenance superintendent.
3. All electric power cords must be inspected before use. Do not use power tools with
frayed cords, cords with exposed wiring, power tools with cords not properly secured
to the tools, or power tools with defective electrical plugs.
4. Tools and jigs especially designed for a specific purpose should be checked by a quali-
fied person to ensure that there are no inherent or hidden safety hazards.
5. Proper and appropriate personal protective equipment must be worn when using all
tools.
6. All tools must be cleaned and properly stored after use. Each tool must have its own
storage area to prevent damage. This is particularly important with power tools.
7. Tools must not be used beyond their manufacturer’s designed capacity since such use
may create a personal hazard. Tools must be used solely for their intended purpose.
The designed capacity of tools must not be exceeded by unauthorized attachments.
8. Power drills, disc sanders, grinders, and both circular and chain saws must be oper-
ated with deadman controls that require constant power pressure.
9. Circular saws and chain saws must not be equipped with devices that lock onto the
operating controls.
10. Power saws, grinders, and other power tools must have proper guards in place at all
times and must be properly grounded. Those with automatically adjusting guards must
be inspected for proper movement.
11. Power tools must be hoisted or lowered by hand line and never by the electrical cord
or hose.
12. Inspect the fuel system of all fuel-powered tools before use. Look for leaks and prop-
erly fitting petrol tank caps.
13. All fuel-powered tools must be shut down while being refueled. Smoking is prohibited
during refueling operations. Other nearby sources of ignition, such as burning and
welding, also must be halted during refueling operations.
14. Power tool bits and blades should never be carried in a pocket. They should be carried
in a toolbox, cart, carrying belt, tool pouch, or in the hand with points and cutting
edges away from the body.

CSP0000419-06
3.17
Using Hammers and Bars in Close Quarters
Work gloves (cotton or leather)
Introduction
Hammers and bars can be used throughout the plants. Bars may be used as levers to pry ob-
jects. The use of these tools can be hazardous, and the hazards are greatly increased when
they are used near other equipment, structures, or personnel. When these tools are used in
close or restricted quarters, extra care must be taken to prevent injury (e.g., being struck by
the tools or caught in a pinch point).
Instructions
1. Thoroughly examine the area in which the work must be done. See how much room
there is to work overhead and on each side. Clean up spills in the area, particularly oil
or grease that can cause slippery footing. Make sure the area is well lit and ventilated.
2. If the work is to be done in, on, or near powered equipment, lock it out in accordance
with lockout/tagout procedure.
3. Wear gloves whenever using a bar or hammer and make certain that your safety
glasses are on.
4. Use only bars that are in good condition. They should be free of sharp snags and have
ends that are not badly mushroomed. If necessary, bars should be sharpened and
properly shaped before use.
5. Do not stand on a bar or jerk it to increase the leverage. Do not straddle the bar or
use it from between your legs.
6. Keep hands and other parts of your body clear of striking points when using a ham-
mer.
7. Do not hammer on any part of the bar except the proper end.
8. Do not hammer on any part of another hammer. Hammers are made of very hard ma-
terial and are designed to hit only softer material. If used to hit other hammers, their
hardness can cause them to splinter, which can result in dangerous flying metal frag-
ments.

CSP0000419-06
3.18
High-Pressure Air
Goggles or face shield
Ear protection
Introduction
Every employee should understand the potential hazards related to working near air compres-
sors, high-pressure pipelines, and vessels, and should take the necessary precautions. The
operator must know the necessary precautions to take. Air escaping from a high-pressure
pipeline, tank, or vessel is extremely dangerous because of its high-energy content and its
ability to rapidly turn small leaks into major ruptures.
Instructions
1. Keep away from air leaks of any kind. If you observe one, caution-tape the area to
keep other personnel away.
Mandatory!
Do not attempt to investigate the cause of a high-
pressure air leak while the tank, vessel, or pipeline
is under pressure.
Do not tamper with relief valves or place any part of
the body over them. Do not paint relief valves.
2. Immediately notify your supervisor.
3. Only qualified and authorized personnel must test and inspect safety relief valves in
accordance with the manufacturer’s recommendations and company procedure. The
shift supervisor should be consulted if there are any doubts about these valves.
4. Before performing maintenance on equipment under pressure, follow lockout/tagout
procedures for isolating and depressurizing equipment.
5. High-pressure equipment and piping are normally equipped with vents, drains, and re-
lief valves that allow for the pressure to be relieved. Before opening the valves, ensure
that there is no measurable pressure showing on the gauges. Make sure that no one is
near the discharge openings.
6. Hearing protection must be worn when venting air.
7. Confirm that air hoses are the correct size and that the pressure rating and connec-
tions at the ends are in proper order.
8. Never use air hoses and lances in a playful manner. Air pipes frequently contain small
particles of rust and metal that can discharge at high speed and cause serious injury.
9. Never use high-pressure air for cleaning clothes or equipment. High-pressure air can
blow small particles of dirt through your skin and into your bloodstream.
10. Never use high-pressure air hoses unless there is a safety system for anti-whipping
protection installed.
11. The couplings used for high-pressure air hoses must be correctly secured. It is prohib-
ited to improvise the means of connecting these hoses.
12. The stamped pressure settings on all relief valves must be clearly visible for required
periodic inspections.

CSP0000419-06
3.19
High-Pressure Water
Goggles or face shield
Introduction
This procedure is to acquaint employees with the potential hazards of working around high-
pressure water. Water under high pressure is particularly dangerous, and the force exerted by
the stream can cause injury to personnel and equipment.
Instructions
1. Keep away from leaks along high-pressure water lines, tanks, vessels, and systems.
2. If a leak is observed, notify your control operator immediately so that the system can
be inspected right away and the problem corrected quickly. Isolate the area by using
caution tape to keep personnel away. Switch to alternative-supply equipment if possi-
ble.
Mandatory!
Do not attempt to investigate the cause of a high-
pressure leak while the vessel or pipeline is under
pressure. Ensure that all personnel are a safe dis-
tance away from the leak.
3. If work is to be done on a high-pressure system, make sure that upstream supply
valves are locked closed and tagged out. Supply pumps should be turned off, with the
breaker opened, and tagged out.
4. Equipment and piping are provided with valves, vents, and drains to allow the release
of any entrapped pressure. Before opening and working on pipelines or equipment,
ensure that any pressure has been safely vented and that pressure gauges read zero.
Be extremely careful that no one is near a discharge point.
5. Leaks may develop at flanges, around outlets, at valves, etc. If these are on the dis-
charge piping, stand clear of the leak.

CSP0000419-06
3.20
High-Pressure Hydraulic Systems
None
Introduction
Hydraulic fluid under high pressure is potentially dangerous. When hydraulic fluid under high
pressure escapes the system through a leak, it exerts a force that can cause injuries and
damage equipment.
Instructions
1. Keep away from leaks along high-pressure hydraulic lines. If any leak is observed,
immediately investigate the system and correct the problem. Report any detected
leaks to the supervisor and to the maintenance department.
2. If work is to be done on a high-pressure hydraulic system, upstream supply line valves
must be closed and locked out. Hydraulic pumps must be turned off and locked out,
provided they do not also supply other parts of the system where there are no leaks
and/or where interruption of hydraulic pressure could pose a problem. Closed valves
and shutdown pumps must be locked out in accordance with the company lock-tag
procedure.
3. Equipment and piping are provided with valves, vents, and drains that allow the re-
lease of entrapped pressure. Make certain there is no pressure on the system (pres-
sure gauges read zero) before opening and working on equipment.
4. Leaks may develop at hose connections, around outlets, at valves, etc. Stand clear of
the leak.
Mandatory!
Do not attempt to find the cause of a leak while the
system is under pressure.

CSP0000419-06
3.21
Overhead Cranes and Rigging Practices
Gloves (when rigging)
Introduction
The purpose of this safe job procedure is to give overhead crane operators precise safety
rules.
Responsibility
Only one operator is responsible for any given crane operation. That person is ultimately re-
sponsible for the entire job and must ensure that it is completed in a safe fashion. The opera-
tor is responsible for ensuring that the daily inspection routine for the crane has been com-
pleted and for inspecting the components of the hoist. The operator must run the equipment
correctly, designate the responsibilities of the crew members, ensure that all personnel in the
path of the load have been cleared out, and ensure that the job has been properly concluded.
The operator must designate no more than one person as the signal person and must receive
signals from that person alone. The exception is an emergency signal (such as a signal to
stop), which can be given by anyone and must be acknowledged by the operator.
Crane Operation
1. Efficient and safe overhead crane operation requires concentration and a rigid applica-
tion of established practices and rules of safety. Safe crane operation is the operator’s
responsibility. Where an operator and a rigger or spotter are working as a crew, the
ultimate responsibility is with the operator who handles the controls of the crane.
2. Do not operate a bridge crane:
• With an uncorrected sight or hearing disability.
• Without training and authorization to operate the crane.
3. Each day, the first user of any crane must make a thorough inspection and complete a
preoperational checklist.
3.1. Be sure to use the correct control for the crane. Try the trolley left or right. If
there is no movement, find out what is wrong (the wrong remote control may
be in use).
3.2. Check wire rope and hooks (refer to the following section on rigging).
3.3. Check the limit switches without a load on the hook. At slow speed, run each
travel and hoist motor to its limit. If any limit switch is not working, tag out
the crane and report the situation to a supervisor immediately.
3.4. Check the brakes with each load: raise the load just clear of the resting posi-
tion and then watch to see if it lowers itself.
4. Make sure pendant controls are not interfering with rope movement.
5. Pan the lift through the entire crane and load movement. If any part of the lift opera-
tion passes into an area that does not have complete visibility from the operator’s po-
sition, has restricted access, or may pass over a personnel access way, an observer
must be assigned and/or appropriate barriers placed before the lift begins.
6. To avoid swinging, place the crane directly over the load before lifting it.
7. Check that all hooks are safe and that loose materials have been removed from the
load before starting a lift.
8. Sound the horn to give warning that there is a load to be lifted, lowered, or moved. If
people are working in the area, give them time to move away. Verify that the area is
fully cleared before moving the load.

CSP0000419-06
3.22
9. Operate controls smoothly and gradually to avoid swinging the load.
10. When the load is ready to be hoisted, take the slack out of all components and then lift
very slowly, watching for lateral movement (swinging) of the load. Once the load is off
the ground and at a reasonable travel height, begin travel at slow speed. When lower-
ing the load, go slowly in the latter stages.
11. Before traveling with the load, make sure that the load is high enough to clear any ob-
stacle below. When traveling with a load, have a spotter precede the load to warn
anyone near its path.
Mandatory!
Do not carry a load over anyone or over any rotating
equipment.
12. When starting or slowing down, do so gradually. For small movements, inch the load
(advance step by step).
13. To stop a swinging load, move the hook toward the load just as the load is at the out-
side of its swing and begins to come back toward vertical. Move approximately half the
distance of the swing and then stop. The load should stop swinging. If the load is
swinging and you are about to begin travel, wait until the load just starts to swing in
the direction of travel, then begin movement in that direction. No further corrections
should be needed.
14. Always obey a Stop signal, no matter who gives it.
15. The lifting cables of the bridge crane must be kept vertical. Do not use the overhead
crane to pull any load sideways.
16. Never lower the hook so far that it leaves less than two complete circles of cable in the
drum. If the cable becomes unwound, make sure it is rewound in the right direction.
(If it is rewound in the wrong direction, the high-level limit switch will not work.)
17. Use tag lines on all loads that could rotate and hit other objects.
18. Loads should have no unattached pieces on board. If loads are lifted on a pallet, all
pieces of the load should be tied down.
19. Never carry loads heavier than the overhead crane capacity.
20. Never disable or remove limit switches.
21. Never lift more than the safe working load capacity of the cables, chains, etc.
22. Never leave an unattended load hanging from the overhead crane.
23. Use the standard overhead crane hand signals when operating the overhead crane.
(Refer to Figure 3.1.)

CSP0000419-06
3.23
Figure 3.1. Hand signals

CSP0000419-06
3.24
Rigging Practices
The size of the load is the main factor, though not the only factor, to consider when selecting
the type of equipment to be used to rig the load. The weight of the equipment must be in-
cluded in calculations when determining the choice of rigging equipment. It is far better to
overrig for a task than to underrig.
1. Determine the center of gravity. If the load is uniformly shaped, the center of gravity
is at the center of the shape. It may be difficult to determine the center of gravity of
oddly shaped objects, however. Ask the supervisor if there is any doubt as to the loca-
tion of the center of gravity. (See Figure 3.2.)
Figure 3.2. Center of gravity
2. Make sure that the hook and lift points (points of attachment) are vertically above the
center of gravity. It is not always possible to place the lift points directly above the
center of gravity, so it may be necessary to take additional precautions. This is usually
not a problem. Support can be maintained with additional chokers.

CSP0000419-06
3.25
3. Determine the hitch to be used. Often the equipment has lift points provided for the
purpose, or the problem is relatively simple. Sometimes, however, the problem is
more complex. Figure 3.3 shows the six hitches most often used.
Figure 3.3. Hitches
4. Determine the loads of the hitch components. The main components of most rigging
hitches are slings. In order to determine the proper sling, several factors must be
taken into consideration. They are:
4.1. The Number of Slings to Be Used: If more than two slings will be used, as-
sume that all of the load could be taken by two of the slings.
4.2. Sling Angle: This is the angle between the sling and an imaginary plumb line
from the hook. For a given load, tension in a sling is least when the sling is
vertical (sling angle is 0 degrees). As the sling angle departs from vertical, the
tension in the sling increases. Once the sling angle passes 60 degrees, the
tension in each sling is greater than the weight of the load. Figure 3.4 illus-
trates the effects of various sling angles applied to a 1,000-kg (2,205-lb) load.

CSP0000419-06
3.26
Figure 3.4. Effect of sling angle on loads

CSP0000419-06
3.27
Figure 3.5 is an example of how to calculate load.
Determine the tension by the following method:
4.2.1. Measure the vertical distance from the hook to the plane in which the
hitch points lie.
4.2.2. Divide the length of the sling by the value measured in Step 4.2.1
above.
4.2.3. Multiply the result calculated in Step 4.2.2 above by the load that the
sling must support.
Figure 3.5. Load calculation
4.3. Bends: Tension increases when slings must go around sharp corners or bends.
The tighter the radius of the bend, the more tension produced. Use softeners,
or corner irons, to alleviate sharp bends. In a choker hitch, the bend made by
the choker increases the sling tension by about 33 percent. A basket hitch re-
duces the tension (assuming there are no sharp bends at the bottom and both
legs are vertical) by distributing the load evenly through each leg.

CSP0000419-06
3.28
5. Select the appropriate equipment. All slings, connectors, eyebolts, turnbuckles, shack-
les, chain falls, and other support equipment in a leg must be able to support the ten-
sion that particular leg will carry. The capacity of the rigging equipment should be
written or stamped legibly on the piece. If it is not, check with a supervisor.
6. Inspect all rigging equipment for signs of wear or damage.
6.1. Wire Rope Slings: Check for:
• Kinking.
• Bird-caging or unraveling.
• Broken wires.
• Overstretching.
• Damaged eyes or eye splices.
• Corrosion.
• Excessive wear (shiny or smooth spots on the rope).
6.2. Chains: Check for:
• Wear (diameter less than 90 percent of new).
• Overstretching (less than 10 percent stretch is allowed).
• Cracks.
• Broken welds.
6.3. Hooks, Shackles, Eyebolts, and Turnbuckles: Check for:
• Spreading of the throat (15 percent maximum is allowed).
• Safety latch in place on all hooks.
• Cracking.
• Twisted shank.
• Cracking or distortion of the eye in an eyebolt.
• Damaged threads.
• Improperly substituted shackle pins (a bolt or anything other than a
proper shackle pin is not allowed).
7. If eyebolts are used, shackles must be used to attach the eyebolt and the sling. Align
the eye of the eyebolt with the eye of the sling to avoid twisting force when the strain
is taken up.
8. If there is any sling angle, use a shoulder-type eyebolt. The shoulder should make
complete contact with the load. An eyebolt should not be used if the sling angle ex-
ceeds 45 degrees. Use straight-shank eyebolts for vertical lifts only.
9. Never put a hook through an eyebolt. A shackle should be used to connect the two.
10. Put shackle pins through the eyes of eyebolts or turnbuckles. The hook should rest
next to the body of the shackle.
11. Shackle pins should be finger-tight, not backed off.
12. Shackles should be positioned for a direct pull, not at an angle.
13. If a sling is used to make a choker, a shackle should be used rather than choking
through the eye of the sling. The shackle pin should go through the eye of the sling.
14. Slings should not be twisted.

CSP0000419-06
3.29
15. A choker should never be forced tighter than its natural fit. If the hitch must be
tighter, use a double-wrap choker hitch or double-wrap basket hitch.
16. Do not attach more than two slings directly to a hoist hook at one time. Use a large
shackle instead.
17. Attach slings with integral hooks so that the hooks turn outwards.
18. Never double-wrap a sling around a hook, eyebolt, shackle, or anywhere where a tight
turn will result.

CSP0000419-06
3.30
Using a Pedestal Crane
None
Introduction
This safe job procedure gives pedestal crane operators precise safety rules.
Instructions
1. Crane safety is the operator’s responsibility.
2. Efficient and safe pedestal crane operation requires concentration and a rigid applica-
tion to the practices and established rules of safety.
3. Supervisors must authorize the operation of industrial equipment after the operator
has been instructed on proper use.
4. Pedestal crane operators must not:
• Operate equipment with an uncorrected sight or hearing disability.
• Operate equipment unless trained and authorized to operate the crane.
5. Do not remove limit switches.
6. Check the pedestal crane (cables and slings) at the beginning of each use. Make sure
all limit switches, brakes, and other safety mechanisms are in good working order. If a
defect is found, report it immediately to a supervisor.
7. Never use the pedestal crane when the limit switches are defective or the cables are in
poor condition.
8. Plan the lift through the entire crane and load movement. If any part of the lift opera-
tion passes into an area that does not have complete visibility from the operator’s po-
sition, has restricted access, or may pass over a personnel access way, an observer
must be assigned and/or appropriate barriers placed before the lift begins.
9. Place the hook directly over the load before lifting it. Otherwise, the load will start to
swing.
10. Before moving the load, make sure that the load is high enough to clear any obstacle
below. (Do not carry a load over anyone.)
11. When starting or slowing down the swing, do so gradually. For small movements, inch
the load (advance step by step).
12. Always obey a Stop signal—no matter who gives it.
13. Operate controls smoothly and gradually to avoid swinging the load. Take up the slack
in cables before lifting loads.
14. The lifting cables of the pedestal crane must be kept vertical. Do not use the pedestal
crane to pull sideways.
15. Never lower the hook so far that it leaves less than two complete circles of cable in the
drum. If the cable is unwound, make sure it is rewound in the right direction; other-
wise, the high-level limit switch will not work.
16. Verify that the area is clear before moving the load. If people are working in the area,
give them time to move away. Ensure that the area is clear before proceeding with the
lift.
17. Never lift heavy loads that could overload the pedestal crane’s capacity. Allow for addi-
tional loading to break free fitted parts.
18. Never lift more than the safe working load capacity of the cables, chains, etc.

CSP0000419-06
3.31
19. Check the brakes by moving the control to the Neutral position after a lift of several
millimeters. If the load does not move, the brake is working properly.
20. Never leave a load hanging from the pedestal crane unattended.
21. It is the operator’s and rigger’s responsibility (if a rigger is used) to check that all
hooks are safe and that all loose materials have been removed from the load before
starting a lift.
22. Never use the pedestal crane when the switch has been tagged with a defective
equipment note.
23. Use the standard crane hand signals when operating the pedestal crane. (Refer to
Figure 3.1.)

CSP0000419-06
3.32
Wire Hoisting Rope
Leather work gloves
Introduction
Wire ropes must be inspected every 3 months. The exterior of wire ropes must be cleaned and
regreased every 3 months. Always wear leather gloves when handling wire ropes.
Abuse and neglect are the two chief enemies of wire rope. The rope can be abused in numer-
ous ways, such as careless and improper reeling and unreeling, use on sheaves that are worn
or of incorrect size, improper storage, bad splicing, etc. Neglect in almost every case means a
lack of lubrication.
Avoid adverse handling conditions such as:
• Jerking.
• Allowing slack in the rope.
• Accelerating the load too rapidly.
• Allowing impact (from sudden stopping of the load).
• Permitting ropes to drag over obstacles, causing reverse bends.
• Allowing wire rope to become wet by running the rope through water.
• Exposing wire rope to acid or alkali fumes.
• Allowing ropes to become overheated either by friction or by subjecting the ropes to ex-
cessive heat of any kind.
• Shifting operating ropes from one job to another.
Unloading, Storing, Uncoiling, Unreeling, and Installing
1. When unloading, use web slings to unload steel wire ropes. The hook of a crane or the
prong of a forklift truck might damage the rope.
2. Ropes should be stored in a clean, cool, and dry place. They must be kept clear of the
floor. Ropes stored outside must be protected against rain.
3. Uncoil wire rope by using an uncoiling stand or by rolling the coil along the ground.
Make sure the ground is clean.
4. Unreel wire rope by using an unreeling stand.
5. Never unwind wire ropes without rotating the coil or reel. Otherwise, the rope will tend
to form loops during installation or service. When pulled taut, the loops form kinks.
6. During installation, the rope should travel from the top of the reel to the top of the
drum or from the bottom of the reel to the bottom of the drum. A reverse bend cre-
ates problems.
7. The first operations with a new rope should be carried out with low loads.

CSP0000419-06
3.33
Inspection
Rope inspection books must be kept for all ropes. The result of each inspection must be re-
corded in these books, which must also contain the work certificates supplied by the rope
manufacturer.
The supervisor entrusted with the inspection must ascertain the general condition of the rope
by inspecting its whole length. The following findings must be recorded:
• The wear of external wires.
• Rust.
• Loosening of the wire rope structure.
• Changes in shape.
• Crushed wires and strands.
• Damage to seizings.
The wire rope must be free of grease and dirt in several
places for the inspection.
During intermediate inspections, special attention must be given to the parts of the rope that
run over pulleys or are close to rope suspension or rope attachment points.
A maximum of five broken wires in one lay, or of three wires in one strand in one lay, is per-
missible.
1. Inspect the steel wire ropes regularly. Keep a record of the rope’s diameter, the lay
length, broken wires, or other defects. Discard the rope in time (while it is still safe).
2. Ropes having nodes, contractions, knots, or kinks must be rejected.
See Figure 3.6 for illustrations of rope defects.
Figure 3.6. Rope defects

CSP0000419-06
3.34
Lubrication
To grease a whole rope, the whole length of the rope must be removed from the drum and
laid out. However, it must not be dragged along the ground because dirt and foreign material
will adhere to it, increasing the rate of wear.
If the whole length of the rope is not removed and laid out, the grease should be applied by
brush where the rope runs around the drum or a pulley and the strands should be forced
slightly apart. This allows the grease to penetrate into the rope more easily. Refer to Figure
3.7.
Figure 3.7. Components of a wire rope
Glossary of Wire Rope Terms
The Wire
The basic element of wire rope is the wire, usually round but sometimes with a different
shape. It is cold-drawn to the desired diameter and desired physical properties after special
heat-treating. Most wire is made to one of two grades—Improved Plow Steel (IPS) or Extra
Improved Plow Steel (XIP), which has about 15 percent greater tensile strength. Both grades
are carbon steel that is tough and resists wear. When the wire has a natural finish, it is called
bright. Otherwise it is plated, galvanized, or may have some other surface treatment for spe-
cial applications.
The Core
Rope cores are usually one of three types:
• Fiber rope core—either natural sisal fiber or man-made fiber such as polypropylene.
• Wire rope core—literally an independent wire rope, which is called IWRC.
• Strand core—a typical wire rope strand.
The primary purpose of a rope core is to provide a foundation, or support, for the strands.
The Strands
The greatest differences between wire ropes occur in the number of strands and in the number
and pattern of wires per strand. There are two general types: round strands and strands that
have been formed into other shapes (refer to Figure 3.8). Strand design is a precise engineer-
ing science.

CSP0000419-06
3.35
Figure 3.8. Strand types
The Lay
The word lay is used to describe three physical characteristics of wire rope. It is both an engi-
neering term and a descriptive term. Lay describes:
1. The direction the strands lie in the rope—to the right or to the left. When you look
along a rope, the strands of a right lay rope follow a right-turning pattern. Left lay is
the opposite. It makes no difference from which direction you look (refer to Figure
3.9).
2. The relationship between the direction the strands lie in the rope and the direction the
wires lie in the strands. In a regular lay rope, the wires lie in the opposite direction of
the strands. In a Lang lay rope, the wires lie in the same direction as the strands (re-
fer to Figure 3.9).
Figure 3.9. Right, left, regular, and lang lay

CSP0000419-06
3.36
3. The lay length, or lay, is the length of the rope used by one strand to make one com-
plete spiral around the rope core (refer to Figure 3.10).
Figure 3.10. Lay length
The Seizings
The ends of rope that are to be cut or spliced should be seized with wire (refer to Figure 3.11).
Figure 3.11. Seizings

CSP0000419-06
3.37
Hydraulic Oil
Chemical-resistant gloves
Splash goggles
Chemical-resistant apron
Supplied-air respirator (in confined or enclosed spaces)
Introduction
Hydraulic oil is a petroleum lubricating oil. It is a clear, light-yellow liquid with a faint petro-
leum hydrocarbon odor. When working with or near this material, avoid prolonged breathing of
its vapor, mist, and fumes, and avoid prolonged or repeated skin contact.
Instructions
1. Use chemical-resistant gloves, splash goggles, and a chemical-resistant apron or other
impervious clothing, if needed, to avoid prolonged or repeated skin or eye contact.
2. Before working with hydraulic oil, know the location of the nearest emergency shower
and eyewash station.
3. Immediately wash off affected skin, eyes, and protective clothing. Remove contami-
nated clothing and launder before reuse. After contact with hydraulic oil (and espe-
cially before breaks and meals, and at the end of shifts), always cleanse skin with a
waterless hand cleanser, and then wash thoroughly with soap and water.
Health Hazards
Health studies have shown that many petroleum hydrocarbons and synthetic lubricants pose
potential health risks that may vary from person to person. As a precaution, minimize expo-
sure to liquids, vapors, mists, and fumes.
Prolonged or repeated skin contact with this product tends to remove skin oils, possibly lead-
ing to irritation and dermatitis. However, based on human experience and available toxicologi-
cal data, this product is judged to be neither a corrosive nor an irritant. Hydraulic oil has a low
order of acute oral and dermal toxicity, but minute amounts inhaled into the lungs may cause
mild to severe pulmonary injury and possi-bly death.
First Aid
Eye or Skin Contact
If splashed into the eyes, flush with clear water for 15 minutes or until irritation subsides. If
irritation persists, call a physician. In case of skin contact, remove any contaminated clothing,
and wash skin with soap and water. Launder clothing before re-use. If the product is injected
into or under the skin or into any part of the body (regardless of the appearance of the wound
or its size), the person must be evaluated immediately by a physician as a medical emer-
gency. Even though initial symptoms from high-pressure injection may be minimal or absent,
early medical treatment within the first few hours may significantly reduce the ultimate extent
of injury.
Inhalation
Hydraulic oil has a very low vapor pressure. Vapor inhalation under ambient conditions is nor-
mally not a problem. However, if someone is overcome by vapor from the hot product, imme-
diately remove that person from exposure and call a physician. If breathing is irregular or has
stopped, qualified medical personnel should start resuscitation and administer oxygen, if
available.
Ingestion
If ingested, do not induce vomiting. Call a physician immediately.

CSP0000419-06
3.38
Spills
Recover free product. Add sand, earth, or other suitable absorbent material to the spill area.
Avoid prolonged breathing of vapors and prolonged skin contact. Open all windows and doors.
Keep product out of sewers and watercourses by diking or impound-ing. Advise proper au-
thorities if product enters or may enter sewers, watercourses, or extensive land areas.
Hazardous Chemical Reactions
This product is stable and does not react violently with water. However, avoid contact with
strong oxidants (such as liquid chlorine, enriched oxygen streams, sodium hypochlorite, cal-
cium hypochlorite, etc.) because this contact presents a serious explosion hazard.
Storage
Keep the container of hydraulic oil closed when not in use. Do not store near heat, sparks,
flame, or strong oxidants.
Container Disposal
Do not attempt to clean the containers, because the residue is difficult to remove. Empty
drums must be completely drained, properly bunged, and promptly returned to a drum recon-
ditioner. All other containers must be disposed of in an environmentally safe manner and ac-
cording to appropriate plant policy.
Empty containers retain residue (liquid and vapor) and can be dangerous. Do not pressurize,
cut, weld, solder, drill, or grind such containers or expose them to heat, flame, sparks, static
electricity, or other sources of ignition; they may explode and cause injury or death.
Fire
Use water spray, dry chemical, foam, or carbon dioxide to extinguish the fire. Use water to
keep fire-exposed containers cool. If a leak or spill has not ignited, use water spray to dis-
perse the vapors and to provide protection for people attempting to stop the leak. Water spray
may be used to flush spills away from exposures.
Avoid prolonged breathing of gases, vapors, fumes, or decomposition products. Use a self-
contained breathing apparatus (SCBA) for enclosed or confined spaces, or as otherwise
needed.

CSP0000419-06
3.39
Safety Showers and Eyewash Stations
None
Introduction
Chemical safety showers and eyewash stations are installed in all plant areas, especially areas
where reagents are used. Each safety shower consists of a single high-volume showerhead
and a hand-operated pull lever for opening the water valve. Each eyewash station consists of a
fountain with dual eyewash flush valves.
The showers are available for employees to immediately wash off any chemical (such as caus-
tic soda, hydrochloric acid, etc.) that may spill or splash on any part of them.
Instructions
1. Always know the location of the nearest safety shower and eyewash station in the
work area.
2. Inspect all safety showers and eyewash stations each shift as part of the work area
safety checks in order to ensure that they are functioning properly. If they are not, no-
tify the supervisor. Do not handle chemicals if the safety showers and/or eyewash sta-
tions are not operational unless other safety procedures are implemented.
3. It is important for a worker involved in a chemical spill to get to a shower as quickly as
possible. While proceeding to the shower, try to notify a supervisor or other employ-
ees of the emergency, and ask for their assistance.
4. For a chemical splash in the eyes, the victim’s face must be placed as close as possible
to the dual eyewash valves. Turn on the water using the foot pedal or the hand-
operated valve.
Mandatory!
When using the eyewash station, hold the eyes open
for at least 5 minutes to ensure that all chemical is
removed. Then, seek medical attention.
5. A worker splashed with a chemical must get under the shower fully clothed and must
start the shower by using the pullcord with the handle.
6. Remove affected clothing only after it has been fully saturated with water and most of
the chemical has been washed out.
7. Continue to shower until all residue of the chemical has been thoroughly flushed from
the skin.
8. Advise the supervisor of the incident, and seek medical help to determine the extent of
any injury.

CSP0000419-06
4 Erection
4.1
4 Erection
Special Tools Required
Required Special Tools, Materials and Supplies (Not by FLSmidth)
Belt tension measurement tool
Transit
Torque wrench
Straight edge
Machinist level
“Never Seize”-type compound
Welding equipment
Lifting equipment
Nonshrinking-type grout
Shims
Installation Completed in Accordance With Standards
The flotation cell is to be included into a concentrator, which should be approved according to
the standards applied by the regulatory authorities and FLSmidth.
Local regulations—if more stringent—take precedence over instructions manuals.
For dated references to any publication, subsequent amendments to or revisions of any of
these publications apply to this instruction only when incorporated in it by amendment or revi-
sion.
For undated references, the latest edition of the publication referred to applies.
Modifications
Attention!
Any field modification to components, unless authorized by
FLSmidth, can and will nullify the warranty.

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