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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

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
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
uncontrolled movement of ore
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
incident u1a picking belt
Incident – U1A Picking Belt

U62 Shaft

U62 Ore bin

U1A Conveyor Belt

U1A Ore Chute

current u1a u1b ore control
Current U1A/U1B Ore Control

Chain Block

Bridle

Control Chain

slide8

Bridle

Swing chute

Sling to secure chains

original operation
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.
major principle hazard management
HAZARD (ENERGY)

Water / Material

(Gravitational)

THREATENING EVENT

Uncontrolled Movement of ore

Major/Principle Hazard Management
solutions
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
solution chain control system
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)
chain control system
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.
advantages
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
conclusion
Conclusion
  • Transferability of innovation to other feeder systems – R62 Feeder room, all U/G Chain controlled chutes
  • Questions?