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QMIHS Conference

QMIHS Conference. Hydraulic Semi-Automatic Chain Control System Presented by: Production Shafts & Hoisting Superintendent - Londt van der Merwe Production Crushing & Conveying Supervisor - Bruno de Valter Xstrata Copper, North Queensland 24 - 26 August 2009. Incident.

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QMIHS Conference

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  1. QMIHS Conference Hydraulic Semi-Automatic Chain Control System Presented by: Production Shafts & Hoisting Superintendent - Londt van der Merwe Production Crushing & Conveying Supervisor - Bruno de Valter Xstrata Copper, North Queensland 24 - 26 August 2009

  2. Incident • Date: 13th January 2009 • Place: U62 Feeder Room, U1A Picking Belt • Occurrence: Wet ore was discharged into the U62 surface bin • Result: Uncontrolled movement of ore through U1A chute, sweeping the Operator off his feet causing him to strike his head against a ladder framework

  3. Result – Uncontrolled movement of ore

  4. Result – Uncontrolled movement of ore

  5. Uncontrolled movement of ore • Definition: • This is a hazard that involves the existence of a significant quantity of water, when mixed with a material is likely to be released and flow uncontrollably due to external energies, eg. gravity or pressure. • Consequence: • Serious injury to the Operator • Damage to property/equipment • Business interruption

  6. Incident – U1A Picking Belt U62 Shaft U62 Ore bin U1A Conveyor Belt U1A Ore Chute

  7. Current U1A/U1B Ore Control Chain Block Bridle Control Chain

  8. Bridle Swing chute Sling to secure chains

  9. Original Operation • Risks • Uncontrolled flow of ore - Operators exposed to potential serious injury • Steps taken to prevent/minimise uncontrolled flow of ore introduced additional risks - Manual handling, pinch points, belt isolation & working at heights • Error forcing conditions • Time taken to set up and de-rig sling and chain block was a minimum of 30 minutes • Numerous notifications of wet ore without an event, would amount to the operator dismissing the call to prevent an interruption to hoisting.

  10. HAZARD (ENERGY) Water / Material (Gravitational) THREATENING EVENT Uncontrolled Movement of ore Major/Principle Hazard Management

  11. Hazard and Risk Management Process Work Process Model

  12. Control Framework

  13. Solutions • Prevention • Water control devices are being installed at various strategic points in the ore stream to limit excessive water ingress into the system. • Communication Procedure for operators in the event of wet ore. • Monitoring • A “Vega” radar bin level monitoring and control device has been installed in the U62 ore bin to ensure that the bin levels are being monitored at all times. • 1st Response • Chain Control Systems • Amelioration • As per the current site Emergency Response Plan

  14. Solution – Chain Control System • Two design options of a Hydraulic Semi-Automatic Chain Control System were developed and installed: • Design 1 • Electro-hydraulic Rigid “U” Frame operating from the rear of the chute – U1A (Design option 1) • Design 2 (Preferred option) • Electro-hydraulic Compression frame operating from the front of the chute – U1B (Design option 2 – Preferred)

  15. Chain Control System • Electro-hydraulic Compression frame operating from the front of the chute – U1B • A fabricated compression frame that pivoted above the front of the U1B chute was attached to a hydraulic ram that applied/released pressure to the chains. • The chains were attached to the compression frame thus eliminating the use of the bridle and chain block system that had been in use to control the ore flow. • By raising or lowering the frame the flow of ore is controlled. • To stop the flow of ore through the chute or in the event of an uncontrolled movement of ore, the ram is fully extended compressing the chains against the ore flow. • Total cost - $16 000.

  16. VIDEO

  17. Advantages • Safety is enhanced as the operator can immediately compress the chains to prevent an uncontrolled flow of ore • One Operator – no additional crews required for set-up • Control of the ore can take place from a remote location • Reduction in manual handling operations for the Operator • Operator fatigue levels reduced due to less manual handling operations • The swing chute is no longer required to limit the flow of ore. • System is very easy to operate, minimum training required • In the event of hydraulic failure, operator can revert to chain block operation • Highly cost effective

  18. Conclusion • Transferability of innovation to other feeder systems – R62 Feeder room, all U/G Chain controlled chutes • Questions?

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