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CRITICAL ACTIVITIES REQUIREMENTS REVIEW Main changes in the PTP - 00813 FEBRUARY 2020 | HEALTH, SAFETY AND OPERATIONAL RISKS
CRITICAL ACTIVITIES REQUIREMENTS REVIEW
Main changes in the PTP - 00813
FEBRUARY 2020 | HEALTH, SAFETY AND OPERATIONAL RISKS
INTRODUCTION
In December 2019, the Critical ActivitiesRequirements 01 to 05 were revised.
PTP-00813 has changed the form and content,with the objective of making requirementsmore robust, making them SAFER and fulfillingour value LIFE MATTERS MOST.
This material serves as a support for theoperational areas to know the main changes inCARs 01 to 05 and does not substitute thePTP-00813 for consulting the requirements.
WHY WERE CARs 01 TO 05 REVIEWED?
• 71% of fatalities in the last 12 years were
associated with CARs.
• 84% of N1 and N2 incidents associated with
CARs in the last 3 years were associated with CARs 1 to 05.
1
4
5
8
9
11
12
25
CAR 07 - Machine guarding
CAR 10 - Work with electricity
CAR 08 - Ground stability
CAR 05 - Lifting of loads
CAR 02 - Light motor vehicles
CAR 04 - Lockout, tagout and zero…
CAR 01 - Working at heights
CAR 03 - Mobile equipment operation
Profile of fatalities associated with CARs in the last 12 years
0 2 4 6 8 10
CAR 06 - Confined SpacesCAR 09 - Explosives
CAR 07 - Machine guardingCAR 10 - Work with electricity
CAR 08 - Ground stabilityCAR 04 - Lockout, tagout and…
CAR 01 - Working at heightsCAR 02 - Light motor vehicles
CAR 05 - Lifting of loadsCAR 03 - Mobile equipment…
N2 incidents by associated CAR
2019 2018 2017
MORE THAN 300 requirements for Critical Activities - 01 to 05 -
evaluated by the technical groups of the CARs.
110 NEW requirements for Critical Activities - 01 to 05.
NEW CARS IN NUMBERS REQUIREMENTS IN THE NEW DOCUMENT
6
12
17
14
29
1
9
3
6
5
10
19
27
49
1
18
17
19
30
CAR 04 - Lockout, tagout andzero energy
CAR 05 - Lifting of loads
CAR 02 - Light motor vehicles
CAR 01 - Working at heights
CAR 03 - Mobile equipmentoperation
Altered Excluded New Not changed
NEW CARS IN NUMBERS
96% of NEW requirements are
PREVENTIVE, which act as barriers to prevent events from occurring.
65 % of the changed requirements are of
the type INSTALLATIONS AND EQUIPMENT, which are more efficient to prevent or mitigate the events that may occur in
critical activities.
1
1
3
5
10
18
26
45
0 5 10 15 20 25 30 35 40 45 50
CAR 04 - Lockout, tagout and zero energy
CAR 05 - Lifting of loads
CAR 02 - Light motor vehicles
CAR 01 - Working at heights
CAR 03 - Mobile equipment operation
Requirement category
Preventive control Mitigation control
2%
33%
65%
Classification of inserted and changed
Training Installation/Equipment Procedure
MAIN GENERAL CHANGES
INCLUSION OF ROLES AND RESPONSIBILITIES
ROLES AND RESPONSABILITIES are MANAGEMENT attributions, which are not directly related to the prevention
or mitigation of events that may occur in critical activities, but assist in the
IMPLEMENTATION and MAINTENANCE of the requirements.
The exception occurs when a unit assumes that it will not be able to comply
any CAR requirements.
The non-compliance by the exception criteria must be exceptional, when all
the possibilities of comply the requirement have been exhausted!
EXCEPTION CRITERIA
Important to remember: comply the requirements is
the RULE!
Ensures that non-compliance of the requirement will not generate unsafe conditions, because additional controls have been adopted.
TECHNICAL STUDY WITH JUSTIFICATION AND PROPOSED MEASURES
Ensures that LEADERSHIP knows the risks of non-compliance of the requirement and monitors the operation of the additional
measures adopted.
FORMAL APPROVAL BY THE EXECUTIVE MANAGER
Fulfilling the role of second LINE OF DEFENSE, the SSRO board must also approve the exception, in addition to monitoring VALE's
non-compliance.
APPROVAL BY THE SSRO DEPARTMENT
This flow makes it possible to FOLLOW UP any requirements that are not being fulfilled and ensures that other CONTROL MEASURES
are being adopted to prevent incidents!
STEPS TO THE EXCEPTION CRITERIA
CAR 01 – Working at Heights
The applicability of the CAR 01 requirements has notchanged, but the new document does not containrequirements for activities performed on walkways andelevated work areas.
For work at height in these places, PRO-022565 must beobserved.
The requirements of CAR 01 - Work at Height areapplicable for activities performed by ANCHORAGE,PEOPLE LIFTING EQUIPMENT and SCAFFOLD.
MAIN CHANGES CAR 01 - WORKING AT HEIGHT
• Requirements divided only at Installations and Equipment, People and Procedures.
• Some requirements were requested in a generic way, giving scope for implementation of fragile controls. Example: "Employees must be protected through physical barriers."
BEFORE
• Requirements subdivided according to the type of possible event in the critical activity and according to the type of equipment.
• The requirements were specified, reducing margins for implementing unsafe controls. Example: Isolation and signaling of the area with physical barriers, such as barrier mesh and pedestal. The use of zebra-tape is prohibited.
AFTER
MAIN NEWS OF CAR 01 - WORKING AT HEIGHT
Specific requirements for Anchoring System
The new document, item 1.7.4, established requirements for the planning and installation of the anchoring system, as well as inspections on the accessories of that system.
Requirements for rescue at height
The new document, item 1.7.5, established requirements for cases in which the performer of the height activity
needs to be rescued, in order to provide security for these situations.
Requirements for preventing scaffold collapse and falling people
from scaffold
Due to the series of events that took place on scaffolding at VALE, the new CAR requires control measures to
guarantee the integrity of these structures and the SAFE execution of activities.
Maximum impact force (6kN) applied
to the worker.
Rescue scenarios at height in the PAE.
Guardrails around the scaffold trapdoors to
prevent falls.
EXAMPLES
EVENTS TO BE PREVENTED OR MITIGATED IN CAR 01
The focus of the news requirements for CAR 01 was the prevention and
mitigation of events exclusively related to the HEIGHT hazard.
Requirements related to other hazards have been excluded or
directed to other CAR’s.
11
6
43
Requirements for events in CAR 01
Structure collapse Falling objects/tools Fall of person
CAR 02 – Light motor vehicles
The requirements of CAR 02 apply to the driving of light vehicles on public roads or owned by Vale, including underground or surface mining areas.
As exceptions, the new document presents vehicles that are allowed to access Vale’s site but are not at Vale's service (Uber, for example) and emergency vehicles.
MAIN CHANGES CAR 02 - LIGHT MOTOR VEHICLES
• Requirements divided only at Installations and Equipment, People and Procedures.
• There were no exceptions to the applicability of the requirements
BEFORE
• Requirements divided at severalsubsections, facilitating identification. Example: route requirements, vehiclerequirements, etc.
• List of exceptions for the applicability of the requirements, facilitating the classification of incidents.
AFTER
MAIN NEWS OF CAR 02 – LIGHT MOTOR VEHICLES
Requirements for fatigue collision prevention or unsafe driving
The new document establishes as a requirement systems that prevent or mitigate events due to
drowsiness or undue speed, reducing the probability of events due to these human factors.
Requirements to prevent collision with mobile equipment
Considering the severity of events involving light vehicles and mobile equipment, the new document
establishes requirements for roads and vehicles, in order to avoid this interface.
Specific requirements for operational roads and vehicle
circulation areas
In addition to the Transit Plan, the new document establishes a series of requirements for light vehicle
traffic routes.
EquipmentProximity Alert
Sensor
Segregation barriers between
light vehicles, people and equipment
Telemetry and driver drowsiness detection system
EVENTS TO BE PREVENTED OR MITIGATED IN CAR 02
The focus of the requirements for LIGHT MOTOR VEHICLES is to
prevent or mitigate events that may occur while DRIVING light
vehicles.
4
48
1
Number of requirements for events in CAR 01-Light motor vehicles
Run over Colision Tire explosion
CAR 03 – Mobile Equipment operation
CAR 03 changed its name to MOBILE EQUIPMENT OPERATION. Although some requirements are implemented during maintenance, it is expected to avoid or mitigate the events that may occur during the OPERATION of this equipment.
The requirements for SAFE operation are not just for the equipment, but for the traffic routes and operating areas of mobile equipment.
MAIN CHANGES CAR 03 - LIGHT MOTOR VEHICLES
• Requirements divided only at Installations and Equipment, People and Procedures.
• The implementation of some requirements depended on risk analysis.
BEFORE
• Requirements subdivided at several sections: operational routes and equipment; open sky and underground mine; fire prevention, etc.
• The technical review team considered it necessary to reduce the margin for not implementing a requirement due to risk analysis.
AFTER
OVERLAY OF CARS 01, 05 AND 03 REQUIREMENTS ON EQUIPMENT
The requirements of CAR 03 must be implemented during the
operation of the vehicle, even if the equipment is intended for lifting of
loads.
The requirements of CAR 05 must be implemented for the lifting
equipment present on the truck, as well as during the entire lifting
activity.
The requirements of CAR 03 must be implemented during the
operation of the vehicle, even if the equipment is intended for lifting of
people.
The requirements of CAR 01 must be implemented for the equipment of
lifting people present in the vehicle, as well as during the entire lifting
activity.
Equipment for lifting people and lifting loads must also have implemented the requirements of activities
01-Work at height and 05 - Lifting of loads, respectively.
MAIN NEWS OF CAR 03 – MOBILE EQUIPMENT OPERATIONS
New requirement for prevention of critical events with off-road trucks
Considering the severity of collision involving off-road trucks, the new document presents this requirement as
important critical control to avoid this type of event.
New requirements for high-speed incident prevention
New requirements that prevent or mitigate event caused by human
factor
The new document requires system that prevent or mitigate events due drowsiness, decreasing the probabilities of events due to this human factor.
Location and speed monitoring systems
(telemetry).
Além do Plano de
Operatordrowsiness
detection system.
Anti-collision system with
automatic braking of equipment.
In the previous version of the document only a speed registration system was required. The current document
now requires a monitoring system (management) for off-road trucks and other trucks (including underground
mining).
NEW REQUIREMENTS FOR FIRE PREVENTION AND MITIGATION
Diffuser valve
Thermal Blankets
Shutdown System
The requirements for fire prevention and mitigation are applicable to equipment with a
cabin greater than 1.80 meters, considering the risk of SAFE evacuation of the operator of
the equipment in the event of fire.
EXAMPLES
Prevents overheating of parts of the equipment, preventing the onset of fire.
Prevents the tire from exploding if the temperature / pressure increases during
a fire.
Logic of automatic engine shutdown in case of fire, as a way to mitigate damage.
Due the recurrence of fires in mobile equipment at VALE, the new document
established an exclusive topic about the theme, focusing on OPERATOR SAFETY and
fire fighting professionals.
EVENTS TO BE PREVENTED OR MITIGATED IN CAR 03
The requirements of CAR 03 are focused on OPERATION, considering
the events with real or potentially critical and catastrophic severity
that happened at VALE. Events that occur during MAINTENANCE of mobile equipment will not be
related to CAR 03.
8
3
75
13
5
2
1
1
Events of requirements in CAR 01
Run over Electric shock Colision
Fire crushing Fall of load
Fall of person Intoxication
CAR 04 – Lockout, tagoutand zero energy
CAR 04 changed its name to BLOCK, IDENTIFICATION AND ZERO ENERGY and is applicable for MAINTENANCE or SERVICES activities in installations, machines and equipment where it is necessary to apply de-energization, blocking, labeling, residual energy release and testing procedures in order to ensure control of the potential for a hazardous energy release.
Now, the requirements of CAR 04 are directed to the exposure of other types of energy, in addition to electrical energy.
MAIN CHANGES CAR 04 – LOCKOUT, TAGOUT AND ZERO ENERGY
• The management of the stages of the electric energy blocking process were not specifically described.
• Absence of a requirement that addresses the temporary introduction of energy in machinery and equipment.
• Despite being applicable to exposure to any type of energy, the requirements were not directed specifically to the treatment of potential gravitational energy.
BEFORE
• Inclusion of a specific requirement for implementing a formal system to manage the stages of the electricity blocking process.
• Inclusion of specific requirement for temporary change in the zero energy state.
• Inclusion of a specific requirement for the treatment of gravitational potential energy.
AFTER
MAIN CHANGES OF CAR 04 - LOCKOUT, IDENTIFICATION AND ZERO ENERGY
Specific requirements for dangerous power lockout
The new document states that locks must: be designed for power blocking purposes and have at least 6 cylinders; retain the key when it is open; and be
constructed in non-conductive material when there is the possibility of contact with energized surface.
Specific requirement for lockout matrix
Considering the need to control all energy sources associated with machine, equipment, system or
installation, the new document establishes a requirement for the preparation of
lockout matrix.
Specific requirements for removal of locks of energy sources
In addition to the requirements for lockout, identifying and zero energy, the new document includes the process
of removal of locks of energy sources.
Identification of power sources and
lockout points
Integrity of safetyconditions
Lock out devices
CAR 05 – Lifting of loads
The requirements of CAR 05 are applicable to NON-MANUAL load lifting activities, through its own equipment, leased or rented by Vale, as well as equipment from service providers that are part of the scope of the contract.
The new document establishes exceptions for applicability:
a) Manual lifting; b) Cargo transportation; c) Equipment maintenance; d) Vehicle collision;e) Lifting people.
MAIN CHANGES CAR 05 – LIFTING OF LOADS
• Requirements applicable only to the lifting activity itself.
• There were no exceptions to the applicability of the requirements
• Mention of the RIGGING PLAN as a requirement, but without requiring the minimum content.
BEFORE
• The application covers the preparation of the area and modifications of the equipment that occur before the activity, considering the requirements that prevent or mitigate events in these situations.
• Establishes a list of exceptions, facilitating the classification of accidents.
• Inclusion of the minimum content requirement for the preparation of the RIGGING PLAN.
AFTER
MAIN NEWS OF CAR 05 – LIFTING OF LOAD
Specifications for area isolationSimilar to CAR 01, the requirements for area isolation for
lifting of loads were specified, with the purpose of bringing more effectiveness in isolation.
Requirements for preparing the equipment
The new document establishes requirements that prevent injuries (such as cuts and amputations) when
preparing the equipment.
New requirements for improper loading
The new document establishes engineering or system requirements that prevent movement or fall of the load,
preventing injuries or fatalities due to crushing.
Prohibition of isolating the area with zebra tapes.
Hydraulic boom for articulated crane.
Inclinometer for overhead crane and joystick for munck.
EXAMPLES
EVENTS TO BE PREVENTED OR MITIGATED IN CAR 05
The requirements of CAR 05 aim to prevent or mitigate events that
occur in the preparation or during the LIFTING ACTIVITY. Events that
occur during equipment maintenance are not related to CAR
05.
1
3
6
30
Number of requirement for events in CAR 05
Eletric shock Crushing
Fall of load Fall of equipment
