Please read this before using presentation

1. Please read this before using presentation • This presentation is based on content presented at the 2007 Mines Safety Roadshow held in October 2007 • It is made available for non-commercial use (eg toolbox meetings) subject to the condition that the PowerPoint file is not altered without permission from Resources Safety • Supporting resources, such as brochures and posters, are available from Resources Safety • For resources, information or clarification, please contact: ResourcesSafety@docep.wa.gov.au or visit www.docep.wa.gov.au/ResourcesSafety

2. Toolbox presentation: Classified plant requirements for mining operations and registering classified plant October 2007

3. Introduction Are you confused and unfamiliar with classified plant? If you are then you’re not alone! This presentation provides information on: • Resources Safety’s requirements for registration of classified plant • frequently asked questions relating to classified plant • tips and “rules of thumb” when dealing with classified plant

4. What is classified plant? Classified plant is any: • boiler • crane • hoist • lift • pressure vessel But only certain types of classified plant need to be registered

5. What is registrable classified plant? Basically, three main groups of registrable classified plant encountered on mining operations: • pressure vessels • cranes • hoists and other plant used to lift people

6. What is registration about and why do we register classified plant? • Historically, classified plant has been found to be extremely hazardous when its design, construction, testing, operation and maintenance have been deficient • Basic requirement for all classified plant to be designed, constructed, tested and maintained in accordance with applicable Australian Standard (AS) • Registration of certain types of classified plant – those deemed the most hazardous – ensures they conform to the applicable Australian Standard

7. Registration process • Certain types of classified plant are required to be registered with Resources Safety before being used at mines • About 900 applications are received and processed each year by a small team of Special Inspectors of Mines (Machinery), who review the applications and issue registration numbers on letterhead

8. The team From left: Jim Farnworth (Karratha), Barry Evans (Kalgoorlie), Rod McFarlane (Perth), Brett Boneham (Perth), Scott Kay (Perth), Dino Busuladzic (Perth)

9. Registration process cont. • A considerable number of applications are rejected or put on hold waiting for discrepancies and deficiencies to be resolved before registration proceeds • If after a period of time there is no resolution, application is returned to applicant • Problematic applications consume a considerable amount of time and resources for both the team of inspectors and applicants who are seeking to use the plant at a mine

10. Registration process cont. Elements that must be dealt with when making and reviewing applications: • Authorisation of applicant • Assessment of plant • Application preparation • Application submission • Review of application • Issue of registration number

11. 1. Authorisation of applicant Persons who are deemed to be authorised to apply for registration of classified plant are : • Principal Employer at the mine • Registered Manager • a person authorised and appointed by either of the above Most applications are rejected because the applicant doesn’t have or hasn’t included a copy of their authorisation letter from the Registered Manager or Principal Employer

12. 2. Assessment of plant – pressure vessels • An assessment is required to confirm if plant requires registration • For pressure vessels, consult the General Exemptions–see Resources Safety website in mining section under “Legislation and policy” • A pressure vessel must be assessed in accordance with AS 4343 (will be explained shortly) Use the pro forma application available from the Resources Safety website in the mining forms section – it is a useful guide

13. 2. Assessment of plant – cranes • Powered tower cranes • Gantry cranes with a safe working load greater than 5 tonnes, or bridge cranes with a safe working load greater than 10 tonnes • Any gantry crane or bridge crane that is designed to handle molten metal or dangerous goods • Mobile cranes with a safe working load greater than 10 tonnes

14. 2. Assessment of plant – hoists and other plant used to lift people • Lifts • Building maintenance units • Powered hoists, with a platform movement in excess of 2.4 metres and designed to lift people • Work boxes suspended from cranes • Boom-type elevating work platforms • Powered vehicle hoists • Powered mast climbing work platforms

15. What about hire and contractor’s plant? • There is a General Exemption that deals with certain types of itinerant classified plant; i.e. hired and contractor-owned plant • Exemption applies to what is commonly termed “dry hire” plant (e.g. plant that is not owned by an employer at the mine) • Plant is not used or is at the mine for a period of time not exceeding that specified in Schedule 3 of Regulation 6.40 • An employer at a mine can be the principal employer, any contractor or other party who employs persons at the mine • Unfortunately, crane hire companies who provide an operator to a mine with a crane (“wet hire”) must register their cranes

16. 3. Application preparation • Once a person is authorised, they may prepare the application • Pro forma application is available from Resources Safety website to facilitate preparation of the application – we strongly recommend using this • Regulation 6.34 requires certain documentation to be submitted with any application but there is a General Exemption that allows some flexibility

17. 4. Application submission • All applications should be mailed to Resources Safety with supporting documentation as required • Do not fax or email unless requested by one of our team • Applications should be addressed to: Resources Safety, DOCEP Machinery Safety Section Locked Bag 14 CLOISTERS SQUARE WA 6850

18. 5. Review of application • Please remember that inspectors don’t only deal with classified plant registration applications • Allow a minimum of three weeks for processing, although the turnaround time will usually be less • Applications are commonly sent at the last minute before plant is required to be used because the registration aspect has not been considered adequately • Once received, one of the team reviews the application

19. What happens if there is a problem? • A problem will normally result from one or more of the following: • appropriate authorisation documentation not submitted • incorrect registration documentation from other authorities • incorrect test certificates submitted • Team member will contact applicant to advise of problem and how to proceed in achieving registration • If the applicant doesn’t respond or the matter is not resolved over a period of time, the application may be sent back or filed

20. 6. Issue of registration number • Once person reviewing application is satisfied that it is acceptable, a letter is prepared detailing the issued registration number and other requirements deemed important • Letter typically states some conditions, such as: • plant to be installed in accordance with the relevant Australian Standard • in the case of pressure vessels, there will be a requirement to fit, test and prove pressure safety valve (PSV), also known as a pressure relief valve (PRV) • in most cases, a statutory inspection will be required

21. Are there any exceptions to having to register classified plant? • Yes – General Exemptions have been issued to industry to make regulatory requirements less onerous and compliance easier to achieve, as well as trying to align Resources Safety requirements with other authorities within Australia responsible for plant safety (e.g. WorkSafe WA) • Some General Exemptions make it easier to register classified plant and, in some cases, certain types of plant are no longer required to be registered

22. Pressure equipment

23. What is pressure equipment? Typically, pressure equipment is pressure vessels such as: • air/oil separator tanks on compressors • air receivers • heat exchangers • flash vessels • boilers

24. What are the relevant Australian Standards that apply to pressure vessels? • Applicable standard for the design, construction and testing of pressure vessels is AS 1210 • Prescribed standard to assess the hazard level of a pressure vessel is AS 4343 • Applicable standard for in-service inspection and maintenance for pressure vessels is AS 3788 Tip: If you are responsible for classified plant at your site, make sure your maintenance staff are made aware of these requirements

25. What pressure vessels are registrable? • Pressure vessels categorised as hazard level “A”, “B” or “C” according to AS 4343 • Boilers

26. What about boilers? • The applicable standard for the design, construction and testing of boilers is AS 1228 • AS 4343 is also used to assess the hazard level of a boiler Tip: Many boilers and pressure vessels are designed, manufactured and testing overseas using other design codes If you’re in the market for a pressure vessel or boiler, always make sure that you specify and check that it is designed, constructed and tested to the applicable Australian Standard – otherwise you will encounter problems when trying to register it with Resources Safety

27. Why is AS 4343 so important? • AS 4343 essentially takes into account the following when assessing the hazard level of a pressure vessel or boiler: • internal volume • design pressure • contents Rule of thumb: The greater the volume, design pressure and more lethal the contents, the higher the hazard level Hazard level “A” is the highest and “C” is the lowest requiring registration

28. Pressure equipment in summary and important tips

29. Summary of registration and statutory inspection requirements for pressure vessels • Typically pressure vessels with hazard levels “A”, “B” and “C” must be registered as classified plant with Resources Safety. Under certain circumstances registration with other authorities (e.g. WorkSafe WA) is accepted under special conditions • All typical pressure vessels must be maintained in accordance with AS 3788 • Pressure vessels with an internal volume >150L must undergo a statutory inspection before they are used, and at intervals of three years or less thereafter • Registration application forms are available from Resources Safety

30. Things to check on pressure vessels • Registered pressure vessel should have a registration number marked on it (e.g. P04010, K04011, T04012, C04013) • WorkSafe WA numbers normally appear in following formats: ↑20430 or WP21345 • There should also be documentary evidence of registration from the respective authority available for perusal

31. More things to check on pressure vessels • Keep a logbook (or file or folder) for each pressure vessel • Logbook should contain copies of statutory documentation and information such as manufacturer’s data report (MDR), hydrostatic test certificate (HTC), pressure relief valve (PRV) test certificate and registration letter • Mines are required to keep a classified plant record book for all classified plant, such as pressure vessels • Hirers and contractors have duties to keep logbooks as construction equipment is itinerant Tip: In record book for plant owned by mine, have separate section for itinerant plant

32. What the logbook should contain • A copy of the logbook, relevant excerpts from it or from the classified plant record book can be kept with the plant when its location is changed, ownership is transferred or it goes to a site for a job, but the original should be kept at the office • Records of maintenance, such asinspections, PRV servicing or re-calibration, any repairs, and details of incidents of damage to the pressure vessel • Records of visual inspections looking for defects, such as damage, leaks, weeping cracks, obstructions to PRVs, and evidence of post-manufacture welds, oxy-cutting and grinding

33. Pressure relief valves (PRVs) • PRVs must be installed and proven for correct setting and function in accordance with AS 1210 • Periodic servicing and recalibration and/or replacement is important • Seal from the last test and calibration should be intact • Fitting, adjusting and tampering with these safety devices by unauthorised persons should be forbidden by the company

34. Cranes

35. What cranes must be registered? In order of most commonly registered: • mobile cranes with a maximum safe working load (SWL) greater than 10 tonnes (T) • bridge cranes with a SWL greater than 10 T • gantry cranes with a SWL greater than 5 T • any gantry crane or bridge crane that is designed to handle molten metal or dangerous goods • powered tower cranes

36. Things we check for on mobile cranes • Have all the cranes on site been recorded in the classified plant record book and register? • Are all the cranes registered with Resources Safety and/or WorkSafe WA? • Has the crane been inspected pursuant to regulations? • Does the driver have the appropriate certification or licence? • Is the logbook kept with the crane? • Is the logbook up to date? • Are pre-start checks and daily inspections being performed? • Are there any defects that compromise the safety of the crane? • Are all the lifting chain slings, hooks, shackles, etc. in good order?

37. Hoists

38. What hoists and other plant used to lift people must be registered? In order of most commonly registered: • boom-type elevating work platforms (EWP) • powered vehicle hoists • powered hoists, with a platform movement in excess of 2.4 metres and designed to lift people • work boxes suspended from cranes • lifts • building maintenance units • powered mast-climbing work platforms

39. Things we check for on EWPs(similar to cranes) • Have all the EWPs on site been recorded in the classified plant record book and register? • Are all the EWPs registered with Resources Safety and/or WorkSafe WA? • Have all the EWPs been inspected pursuant to regulations? • Does the operator have the appropriate certification or licence? • Is the logbook kept with the EWP? • Is the logbook up to date? • Are pre-start checks and daily inspections being performed? • Are there any defects that compromise the safety of the EWP?

40. Workboxes suspended from cranes

41. What about man baskets attached to crane booms? • Not deemed to be workboxes suspended from cranes • Not required to be registered with Resources Safety

42. Further information • Go to Resources Safety website and look for “classified plant” www.docep.wa.gov.au/ResourcesSafety • There are safety bulletins and significant incident reports along with general safety information • There is a Classified Plant High Impact Function Audit/Guidelines, which can be emailed to you • If you need help, contact the Machinery/Mechanical Section in the Mines Safety Branch  08 9358 8079  ResourcesSafety@docep.wa.gov.au