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Vehicle Loading Crane Improvements
Mark HillSite Senior Executive
BMA Blackwater Mine
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd2
Fatality at BMA Blackwater Mine
• In April 2002, an Ergon Energy Employee, was fatally injured at BMA Blackwater Mine.
• The Ergon employee sustained extensive crush injuries to his chest.
• These injuries occurred when the employee was trapped against the operator’s control panel by the movement of a Vehicle Loading Crane (VLC)
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd3
Module intended to be removed
Jib extension EWP
Truck
Bed Log Operator
station Outrigger
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd4
Fatality at BMA Blackwater Mine
VLC Controls
Crush area
Jib
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd5
Findings From Incident
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd6
Root Causes
• Human error when the wrong control lever was selected and activated
• Design is such that there is no physical barrier to provide protection if error occurs
• There are no controls to prevent inappropriate use of the unit
• No standard configuration • Movement of levers does not always match travel • No physical limit or switch to prevent movement
into operator zone
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd7
Risks Relate to all industry
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd8
• To implement an engineering control to prevent the boom striking operator.
Resultant Actions
• Need to create a no go zone to prevent the boom from slewing in and around operators controls.• The new modifications should not reduce the efficiency or function of the VLC.
•A system designed to encompass human error in the operation of a VLC.
• A modification that was easy to use and did not introduce new hazards.• A cost effective control that could be used by all industries.
Resultant Actions
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd9
Possible Control Measures
Remote control unitsRemote control units
•Still has potential for crushStill has potential for crush
• Relies on safe behavioursRelies on safe behaviours
• Can create jerky movementsCan create jerky movements
• Umbilicals can be damagedUmbilicals can be damaged
Dead Man Function
• Does not provide a physical stop
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd10
Remote Controls
HIABHIAB
166 XS
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd11
No Go Zone
OPERATE CRANE FROM THIS SIDE
NO GO ZONE
Controls Controls
No Go Zone
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd12
No Go ZoneNo Go Zone
Full operation
Full operation
Zone “A”
Zone “B”
1.
2.
3.
3.
4.
4. 2.
• When operating crane When operating crane at Zone ‘A’ or Zone ‘B’ at Zone ‘A’ or Zone ‘B’ overide switches overide switches prevent boom slewing prevent boom slewing over the Zone. over the Zone.
• The crane still has full The crane still has full operation in other areas, operation in other areas, just not under Zone that just not under Zone that operator is working fromoperator is working from
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd13
VLC Components
PROXIMITY SWITCH• Locates the VLC’s movements
when slewing.
• Communicates with override switch to slow down slewing of VLC into No Go Zone.
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd14
VLC Components
BUMP BAR
Switches on the bump bar allow VLC to operate outside no go zone
The bump bar must be raised to operate crane.
•Cuts hydraulic power if activated
•3 position with neutral required to operate
• Will only allow one control to be used
• Normal operation outside the operator zone is not effected
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd15
Photo’s
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd16
Success of System
System positive
• All Blackwater VLC’s have been fitted with new controls.
• Greatly reduce possibility of accidental injury
• Greatly reduces possibility of unsafe behaviour when operating
• Enables operation from the load side with restriction
• VLC cost comparative to other controls $7 500
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd17
System Issues
• More components which can fail from a maintenance perspective.
• Enforcing Contractor Compliance
•Training of operators
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd18
Future Improvements Planned
• Promote new controls to be implemented by Promote new controls to be implemented by wider industry.wider industry.
• Investigating use of remotes in conjunction Investigating use of remotes in conjunction with no go zonewith no go zone
•Continuing Work on draft Aust Standard for Continuing Work on draft Aust Standard for New ControlsNew Controls
• BMA currently conducting risk assessments BMA currently conducting risk assessments on all equipment to identify and control latent on all equipment to identify and control latent risks similar to the VLC fatality.risks similar to the VLC fatality.
Date – June 2003
File Reference – Qld Mining Industry Health and Safety ConferenceBlackwater Mine
BMA Coal Operations Pty Ltd19
A DEMO TRUCK IS AVAILABLE FOR VIEWING
