1 / 18

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.

valentine
Download Presentation

QMIHS Conference

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 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

  2. 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

  3. Result – Uncontrolled movement of ore

  4. Result – Uncontrolled movement of ore

  5. 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

  6. Incident – U1A Picking Belt U62 Shaft U62 Ore bin U1A Conveyor Belt U1A Ore Chute

  7. Current U1A/U1B Ore Control Chain Block Bridle Control Chain

  8. Bridle Swing chute Sling to secure chains

  9. 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.

  10. HAZARD (ENERGY) Water / Material (Gravitational) THREATENING EVENT Uncontrolled Movement of ore Major/Principle Hazard Management

  11. Hazard and Risk Management Process Work Process Model

  12. Control Framework

  13. 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

  14. 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)

  15. 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.

  16. VIDEO

  17. 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

  18. Conclusion • Transferability of innovation to other feeder systems – R62 Feeder room, all U/G Chain controlled chutes • Questions?

More Related