Implementation of Safety Initiatives

Transcription

1 Klipspruit Dragline Refurbishment Implementation of Safety Initiatives Vernon Carter Section Engineer, BHPBilliton Klipspruit Colliery 21 January 2009

2 Contents / Dragline History / Shutdown Statistics ti ti / Site Preparation / Site Entrance & Lockout / Office Layout & Component Yard / Boom Ramp & Lighting / Good Practice / Morning Mass Meetings, Emergency procedures and Reward & Recognition / Baseline Risk Assessment, On-site Training and Hardhat Colour Identification / Tool and equipment safety / Visible Coaching Leadership and Good Housekeeping / Monitoring wind conditions for Working at Heights and Heavy Lifts / Barricading Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 2

3 Contents (continued) / Mechanical / Operators Cab Windscreen / Boom Walkways / Swing Door access Platform / Machine Roof Access / Rear Sliding Doors / Working in Confined Spaces and Backleg Lugs / Access Scaffolding / Electrical / Boom installations / 6.6kV 6kV Switchgear / Motor Control Centers (MCC s) / Air Cooled Transformers / Fortress Interlock and Component Separation / Machine House Cable Racking / Technical Innovations / Hoist and Drag Pedestals Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 3

4 Dragline History The Klipspruit Dragline is one of three Bucyrus 1570-W Draglines that was used for mining i and rehabilitation ti at Rietspruit it Mine Services. It was first commissioned i in Actual walk started on 16 August 2003, 34 km to Klipspruit, and ended on 27 October 2003 Machine audits were conducted during 2007 and a scope of work defined for the purpose of repairing and upgrading the machine to a condition to operate for another 20 years The scope of work included mechanical, electrical and structural repairs and upgrades Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 4

5 Shutdown Statistics / Shutdown duration 73 Days / Total man hours worked Hours / Total PTO s 625 / Total green cards to date 348 / Hours spent pre-outage preparation: p Baseline risk assessment: 340 Hrs Further work on risk assessments and related: 80 Hrs Technical Preparation 800 Hrs Training +/- 2 weeks. Pre-conference Meetings 40 Hrs / Fatigue Management Hours of work and off days Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 5

6 Site Preparation Office Layout and Component Yard Single point of access Access control and hardhat stickers Alcohol testing Lockout boxes and attendance control Visitors logbook, lockout and induction Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 6

7 Site Preparation Office Layout and Component Yard Office block separated from site where surface mobile equipment operate PPE free area Separate washing and eating areas Easy access to vehicle parking Component yard with one way traffic and dedicated packing area for new and used components No vehicles on site unless escorted Separate areas for sandblasting Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 7

8 Site Preparation Boom Ramp and Lighting Minimise need for working at heights Less time required for constructing access to boom chords Sufficient drainage in case of wet weather Dedicated d traveling ways for cranes and other vehicles Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 8

9 Good Practice Morning Mass Meetings, Emergency Procedures and Reward and Recognition Morning mass meetings to discuss safety issues Discuss major and critical tasks Emergency procedures Fire drills Reward and recognition for good practices Motivation Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 9

10 Good Practice Baseline Risk Assessment, On-site Training and Hardhat Color Identification Oxy Fuel Training Baseline Risk Assessment Hard hat Color Identification WAH Training i Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 10

11 Good Practice Tool and Equipment Safety Specially designed oxy-fuel trolleys Daily tagging of equipment by competent person Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 11

12 Good Practice Visible Coaching Leadership and Good Housekeeping Weekly supervisor walkabout Weekly workforce walkabout accompanied by safety officers Focus on unsafe acts / conditions and good housekeeping practices Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 12

13 Good Practice Monitoring Wind Conditions for Working at Heights and Heavy Lifts Assess wind condition continuously Rigging studies and permits for heavy and tandem lifts Engineered lifting lugs Heavy lift initiatives: Same cranes and operators In-house crane inspected daily Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 13

14 Good Practice Monitoring Wind Conditions for Working at Heights and Heavy Lifts Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 14

15 Good Practice Barricading Solid barricading of areas Easy to move around and set up Neat and tidy Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 15

16 Mechanical Operators Cab Windscreen Test Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 16

17 Mechanical Boom Walkways Access to A-B and C chords Individual sections on rubber mountings allows for: Flexing Easy replacing of segments Challenges Weight Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 17

18 Mechanical Swing Motor Access Platforms Allows safe access to swing motors Eliminates risk of falling at heights Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 18

19 Mechanical Machine Roof Access Required for removal of right hand machine house section Designed by professional engineer Access to propel roof (elimination of vertical ladders) Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 19

20 Mechanical Rear Sliding Doors Sliding doors Rack and pinion Electrically operated Eliminates machine damage due to strong winds No need for mobile cranes to open doors when control system is faulty Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 20

21 Mechanical Working in Confined Spaces and Backleg Lugs Confined spaces code of practice Gas testing equipment Specialised PPE trial Argon welding and fumes Improved ventilation Improved ergonomics and access Improved emergency evacuation Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 21

22 Mechanical Access Scaffolding Minimise the need to work in Bosun s chair Easy access to complete mast Safer access to links for replacement Lifelines Working at heights rescue Used specialized scaffolding contractor for all scaffolding erection, dismantling and daily inspections Used 3rd party scaffold erectors and inspectors for auditing Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 22

23 Electrical Boom Installations Separate lock-out at each landing Selective switching for lights on boom Welding plugs available on every landing eliminates the need for long extension chords Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 23

24 Electrical 6.6 kv Switchgear Oil circuit breakers and fuses replaced with vacuum breakers 5 Switches: Incomer 1 MVA transformer feeder 200 kva transformer feeder Synchronous motor 1 feeder Synchronous motor 2 feeder Remote switching with umbilical chord Intelligent protection Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 24

25 Electrical Motor Control Centres (MCC s) Selective switching and lockout of components Programmable logic controller (PLC) and Scada allows for testing of all components Minimise risk of coming into contact with live electrical components Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 25

26 Electrical Air Cooled Transformers Leaking oil cooled transformers Poses significant fire hazard Complicated maintenance practices Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 26

27 Electrical Fortress Interlocks and Component Separation Controlled access to electrical compartments Eliminated unauthorised switching and entry Sequenced lock-out of components Partitioning of transformers Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 27

28 Electrical Machine House Cable Racking Prevent damage to cables Easier fault finding and traceability of cables Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 28

29 Technical Innovations Hoist and Drag Pedestals Floor Preparation Hoist Gearcase Pedestal Machining of Pedestals Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 29

30 Technical Innovations Hoist and Drag Pedestals Temperature Control Preparing Dams Laser Alignment Final Product Vernon Carter, Section Engineer, BHPBilliton Klipspruit Colliery, 23 February, 2010 Slide 30

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