Safety Aspects of Earthmover Tyres & Rims. Tilman Rasche Senior Inspector of Mines - Brisbane

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Peter Wells
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1 Safety Aspects of Earthmover Tyres & Rims Tilman Rasche Senior Inspector of Mines - Brisbane

2 Background Presentation Content What makes tyre and rims such a challenging asset Recommendations Where to from here?

3 Some hazards are overlooked Click anywhere for movie

4 What makes Tyres and Rims so special? Flexible Pressure vessel Higher inflation pressure = greater stored energy Failure of tyre or rim can have catastrophic consequences Stored potential energy Kinetic energy

5 What makes Tyres and Rims so special? Prone to injury during operation Damage not easily diagnosed special skill & competency Ungainly & heavy considerable manual handling risks need specialised load shifting equipment

6 What makes Tyres and Rims so special - cont? Assembly from several components integrity vital Tyres = Rubber = poor heat conductor Rims = Steel = very good heat conductor Considerable fuel source hard to put out Specialist maintenance (& training!) Tyres remain a critical asset Higher frequency maintenance = exposure = risk

7 What makes Tyres and Rims so special - cont? What about Second hand tyres Repaired tyres New untried type of tyres and manufacturers Limited choice of compounds Third Party Risks = Latent Conditions This will hurt!

Accident & Incident Analysis History to predict where we need to focus risk & safety management past, present & future ACARP sponsored project BMA & XSTRATA Klinge & Co 2006/07 82 public domain case

8 Accident & Incident Analysis History to predict where we need to focus risk & safety management past, present & future ACARP sponsored project BMA & XSTRATA Klinge & Co 2006/07 82 public domain case studies 19 years Australian & International data sources All reports varied in detail & technical accuracy Data ex industry incident databases found not specific enough to warrant use in this analysis! C15046 Tyre related Accidents and Incidents a study with recommendations to improve tyre and rim maintenance and operational safety of rubber tyred equipment

ICAM Analysis All incidents re-analysed ICAM approach Tabulated strict taxonomy to enable analysis and future update of database (consistency) Consequences, Contributing factors & Root Causes

9 ICAM Analysis All incidents re-analysed ICAM approach Tabulated strict taxonomy to enable analysis and future update of database (consistency) Consequences, Contributing factors & Root Causes Prevention LTA Organisational factors LTA Task or Environ. Conditions LTA Individual or Team actions LTA Absent or Failed Defences Initiator M itigators, Confinem ent Beyond Engineering Controls Hazard Latent Conditions Incident Loss M ishap, Accident

10 Figure 4 - Main Categories of Tyre and Rim Related Incidents & Accidents Tyre Fire 6% Apparent Explosion of flammable propellant inside tyre 1% Equipment. Fire 2% Pyrolysis 20% Non fire related incident/accident 71% n = 82

11 Figure 2 - Actual & Potential Consequences to Tyre & Rim related Incidents & Accidents Equipment Damage 6% Loss of vehicle 2% Injury 9% Potential Fatality 50% Fatality 33%

12 Figure 5 - Organisational Factors LTA legal requirements, commitments and document control 2% LTA monitoring, audit and review 2% LTA design, construction, commissioning 7% LTA Crisis & Emergency Mgt 8% LTA change management 1% LTA communication, consultation and participation 1% LTA Inspection 1% LTA suppliers, contractors and partners. 1% LTA maintenance 52% LTA operations 8% LTA aw areness, competence and behaviour. 17% LTA Organisationa l factors LTA Task or Environ. Conditions LTA Individual or Team actions LTA Absent or Failed Defences

13 Figure 3 - Fatalities & Potential Fatalities - Root & Contributing Causes LTA mat testing/fatigue NDT Heating of wheel assembly or wheel studs LTA matching of assembly components. LTA rim integrity LTA deflation practice. Uncontrolled handling of tyre (LTA grip). No NDT schedule Tyre low pressures Contact with Powerline LTA positioning of crane operator. Seized or overheated brake, overheated electric motor Incorrect jacking LTA procedure LTA training Overpressurisation of tyre or rim Tyre environment - severe conditions causing tyre Failure of tyre or tube repair. LTA / No support equipment other than jacks LTA chocking of vehicle LTA integrity tyrehandler Confined working environment. Use of chemical tyre sealant/propellant/hot work. Driving without due care Inadequate torque Inflation using oxygen. LTA fitment insufficient cleaning of mating surfaces. Spillage of fuel onto hot engine. Tramp material left in tyre cavity. Tyre fatigue Zipper failure Crane not stabilised Abnormal operating conditions LTA dismantling 2 piece ind. rim LTA jack design Elevated Operating Temps Incorrect installed crane controls Fitted assys received, no check Uncertified lifting equipment LTA communication work teams Contributor to Potential Fatality Contributor to Fatality Note: a fatality or potential fatality can have a number of root and contributing causes

14 LTA mat testing/fatigue NDT Heating of wheel assembly or wheel studs LTA matching of assembly components. LTA rimintegrity LTA deflation practice. Uncontrolled handling of tyre (LTA grip). No NDT schedule Contact with Powerline LTA positioning of crane operator. Seized or overheated brake, overheated electric motor Incorrect jacking LTA procedure LTA training Overpressurisation of tyre or rim Tyre environment - severe conditions causing tyre Fil ft t b i Figure 3 - Fatalities & Po

15 Rim Integrity critical to Safety Cracks in rim jewellery and base

16 Reviewed AS4457 now available Was reviewed following Queensland fatalities AS4457: Earthmoving Machinery Off the road wheels, rims and tyres Maintenance and repair Part 1: Wheel assemblies and rim assemblies Risk based ~ Queensland mining legislation Deflation vs Handling (-- OEMs) Non-destructive testing and unique identification AS4457: Earthmoving Machinery Off the road wheels, rims and tyres Maintenance and repair Part 2: Tyres Maintenance of in service tyres Repairability, repair, retreading, marking of tyres

18 Handling of Tyres and assemblies

19 Figure 22- Absent Failed Defences 8% LTA Hazard identification LTA rescue 92% LTA Organisational factors LTA Task or Environ. Conditions LTA Individual or Team actions LTA Absent or Failed Defences

20 Pyrolysis Piece of timber left in tyre cavity Latent condition!

21 300 m Pyrolysis Lighting strike Contacting powerlines Heating of wheel studs Overheating wheel motors, bearings Emergency response?

22 Competency & HR Considerable Hazard & Risk - awareness Specialised skill requiring specialised training Training requirement mandated in Queensland legislation MNCG1031A & MNCG1032A - on (& off site latent risk) Refresher training HR is required General awareness is required induction and throughout employment Champions

23 Summary & Recommendations Not widely recognised hazard maintenance & operations Considerable hazard potential Raise Awareness Competency of Tyre Servicemen HR AS4457 NDT Emergency response Excellent safety & business improvement project Equipment Damage 6% Injury 9% Fatality 33% Loss of vehicle 2% Potential Fatality 50%

24 Next Steps Implement as part of your SHMS OEMs must be part of the solution Info is there but needs to be analysed and made available in a ready to use format for sound decision making. 2008/09 DME-UQ-Klinge ACARP project to make this info more readily available for decision makers EMESRT Earthmoving Equipment Safety Round Table design solution oriented - OEMs

25 Thank You, & Have A Safe Trip Home

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