Hazardous locations, situations• Plant consists of following Locations• Entry to feed hopper• Feed hopper• Feeder• Crusher• Screen• Scrubber• Classifier• Slurry pump• Hydro cyclone• Slurry thickener• Tailing pump• Plus lot of Belt Conveyors

Hazards &LocationsPlant consists of following Locations

Entry to feed hopperFeed hopper

FeederCrusherScreen

ScrubberClassifier

Slurry pumpHydro cyclone

Slurry thickenerTailing pump

Plus lot of Belt Conveyors

• Every location if not properly designed,maintained, improved will have some open and hidden hazards

• Likewise two or more minor hazards when teamed up turn as major hazard (Oil an sloping walk way)

• No location can continously remain hazard free. Familiarity leads to complacency and in turn to accidents. Hence we should impart continous refresher training

• Also a location which is safe against slip in dry season may present slip hazard in monsoon.

• Plant spillages are yet another hazard• Accidents happen when we try to avoid getting

them on us• Spillages below belt or transfer points pose

hazard . Workers try to clean below the belt during operation and get caught. The preventive measure would be to eliminate spillage by proper controls

• Proper lock out switches should be made available to avoid inadvertant starting of equipment at the time of maintenance

HazardsMoving equipmentTransmission belts

Conveyor beltsNip pointsFall of men

Fall of materialWalkways

Cross oversMachine guarding

ScrubberCarrier roller protection and lubrication

GuiderollerDrive guardingFencing around

Cleaning arrangements

Plant start up procedureSequencingInterlockingSiren and timerVisibility of equipmentsLock out taggingAmmeter and logging of current consumption

BenchBHQ intrusionsBHQ weathered quartzite veins/bandsdensity of traffic highdrill and loading area too close (Noise and truck control)dust suppression poordyke intrusionembankment weakexcavator horizontal distance between benches within swingheight beyond bucket reachno or poor embankmentramp too narrowramp too steeptoe hardtoo long reversesToo many trucks reporting to one excavator resulting in chaosToo many trucks running while shifting of excavatortruck placement close to high wall/operator on high wall sidetrucks need to come to edge to reverseUncontrolled traffic all around excavator while workingwidth less (Narrow for traffic)

Improper preparation of primerin correct distribution of delaysCharging wet hole without flushing or cartridging excess ground vibrationconnection D cord to trunk line inefficientfly rock outside danger zonefree in face favour of dipImproper base for shelterImproper blaster shelter locationImproper or weak base below blaster shelterIn experienced helpers in blastingin non scheduled timeinsufficient sentriesneighbour mines not communicatedno sub drilling or under chargeperformance not linked with charge and analysedPoor mixing of ANFopost blast inspection improperpost blast return too earlyShelter in windward direction

Blasting

post blast return too early

Shelter in windward direction

sirens or other warning systems not used

static /stray currents

stemming material very coarse

too early to take charge to site

too late to take explosives to site

too many areas to clear

too many people involved in charging

too much of fly rock inside danger zone

use of damaged explosive

shelter approach is obstructed

shelter too far away

Blast

Bench lateral Gradient steep and draggingIn competence of driverIn correct parking-Slope without chock in wheelsIn sufficient parking spaceIn sufficient/improper checklistNarrow roadNon provision of body level indicatornot checked before starting or after repairsOver loadPoor braking due to bad worn out tyrePoor visibility due fogPoor visibility due glare by excess lightingPoor visibility due raising or setting sunPoor visibility due scratches in wind shieldPoor visibility due to bad road lightingPoor visibility due to dustPoor visibility due to operator seat positionPoor visibility due to poor light fixture

Hauling

Poor visibility due to sharp turningPoor visibility due to steep change in gradientRoad on soft soil not compactedRoad rut formationRoad surface badSkiddingSteeper gradientToo many persons in cabinUnwanted material storage in cabinbody boulder stuck up due to tail gatebody extended shifting C.Gbody not cleaned regularly, wet material stuck up resulting in topplingBonnet holder defective in truckBrake defectivebrake testing bay is not isolatedchecking battery by short circuitingchecking fan belt without operators knowledgeClutch poor

Hauling 2

Dumper critical item repairs mostly outsourcedDump Embankment height in sufficientDumper empty not giving way to loaded from opposite directionDumper engine or components mounting without precautionDumper engine or components removal without precautionDumper engine/starter ,alternator access poorDumper foot board rungs over lappingDumper foot board rungs slipperyDumper foot board rungs too high from ground levelDumper foot board rungs unevenly spacedDumper foot board rungs weakgas cylinder storage too close to workshopDumper gauges in operative or erroneoushaul road drain not protectedhaul road median insufficienthaul road no camberhaul road no designated locations for right hand turnhaul road poor or no super elevation

Hauling 3

haul road rain water not divertedhaul road too sharp hair pin bendshaul road water tanker reversing down gradienthelper checking Dumper while waiting in minesDumper helper driving without licenseDumper helper getting down in motionDumper helper taking rest in the bodyDumper parked side by side waiting for loadDumper Hydraulic hose bad clampingDumper Hydraulic hose failure due to excess length/short lengthDumper Hydraulic hose thread depth in sufficientDumper hydraulic oil topping up with raised body and no chocksDumper Ill fitting rear view mirrorDumper In sufficient pre shift inspectionDumper jump starting without precautionDumper Leaky tail gate resulting in spillage and dustDumper load kept on hydraulic jack and working belowDumper load kept on hydraulic jack and working below and jack not vertical

Hauling 4

Dumper operator unaware of defectsDumper load kept on hydraulic jack and working below and wheel not chockedDumper mechanic repairing without informing driverDumper oil leaking on alternatoroperator emotionally upsetoperator intoxicatedDumper overload ,spillage of sharp material ,tyre burstDumper Poor visibility due to bad wiperDumper replacement of battery without assistanceDumper reverse horn not on auto modeDumper reverse horn sound insufficientDumper operator not lowering body before leaving dumpDumper reversing to excavator before getting signalDumper sufficient tools not available in workshopDumper Tail gate opening manualDumper Tie rod not checkedtoo many people in loading areatoo many people in unloading area

Hauling 5

Dumper too many trucks crowded in loading areaDumper too many trucks crowded in unloading areaDumper trying overtake on haul roadDumper Tyre Grip pattern different in eachDumper rear view mirrors not sufficient to cover blind areaDumper Tyres not alignedDumper Un matched tyresDumper under capacity jack usedDumper use of spurious sparesDumper Welding close to tyre without precautionDumper welding of leaky fuel tankDumper welding shop not protectedDumper Bad positioning of fire extinguisherDumper Bad road manners and parkingDumper Bad unloading area illuminationDumper Door opening arrangement defectiveDumper Driver stressed due to absenceDumper Hard steering due under inflation of tyreDumper Hard steering mechanical

Hauling 6

Excavator body does not have slip proof floorExcavator area illumination poorExcavator Blasted material too bigExcavator too big for trucksExcavator cab not having ROPSExcavator cabin door locking ineffectiveExcavator cabin floor oilyExcavator cabin glass cracked/too many scratch marksExcavator cabin used for storing teeth etcExcavator contractor not maintaining equipment as requiredExcavator contractor operator not fully skilledExcavator controls not operator friendlyExcavator delay in shifting before blastExcavator foot step bent/brokenExcavator operator not trained for change in equipmentExcavator front does not have mesh cloth

Excavator 1

Excavator fuelling time clashing with blasting time

Excavator horizontal distance between benches placed less

Excavator hoses not secured properly

Excavator light of poor quality

Excavator loading higher capacity dumper

Excavator long boom used for denser ore

Excavator not shifted sufficient or facing blast

Excavator operator regularly on extended shift

Excavator operator seat uncomfortable

Excavator illumination on surface producing glare

Excavator operator unable to understand local language

Excavator Operators have night vision problem

Excavator spurious spares used

Excavator too many supervisors/Distraction close by

Excavator too many trucks waiting

Excavator truck placement too far

Excavator 2

Plant no nip guards

Plant nip guard wide mesh larger opening

Plant nip guard too heavy

Plant nip guard not properly fitted

Plant nip guard not fitted back after equipment repairs

Plant nip guard has sharp edges

Plant nip guard obstructing walkway

Plant nip guard no place to keep nearby for repairs

Plant nip guard too tight fitting

Plant nip guard unwieldy in shape

Plant no coupling guards

Plant coupling guard wide mesh opening big and bolts can come through

Plant coupling guard too heavy

Plant coupling guard not properly fitted

Plant coupling guard not fitted back after equipment repairs

Plant 1

Plant coupling guard has sharp edgesPlant coupling guard obstructing walkwayPlant coupling guard no place to keep nearby for repairsPlant coupling guard too tight fittingPlant coupling guard unwieldy in shapePlant Walk way very steepPlant Walk way narrowPlant Walk way no toe guardsPlant Walk way no cross over ladderPlant Walk way cross over ladder rungs too close to structurePlant Walk way cross over ladder does not allow three point contactPlant Walk way Hand rail horizontal member spacing highPlant Walk way hand rail edges sharpPlant Walk way expanded metal hole size too bigPlant Walk way expanded metal uneven fixing

Plant 2

Stack entry not barricaded before loading from below

Stack material boulder and high wet material stack

Stack yard Persons present in close to high wall

Stack too hard and compact for wheel loader operation

Stack floor uneven(not levelled)

Stack area low illumination

Stack area illumination throwing glare for operators

Stack area placement of trucks too close to toe of stack

Stack ore is just wet resulting in continuous change in angle of repose

Stack restarting edge not dressed

Stack restarting undercut not inspected

Stack restarting -first trip unloaded from edge

Ore stack

Stack entry not barricaded before loading from belowStack material boulder and high wet material stackStack yard Persons present in close to high wallStack too hard and compact for wheel loader operationStack floor uneven(not levelled)Stack area low illuminationStack area illumination throwing glare for operators Stack area placement of trucks too close to toe of stackStack ore is just wet resulting in continuous change in angle of reposeStack restarting edge not dressedStack restarting undercut not inspectedStack restarting -first trip unloaded from edge

Stack

Drill Air receiver not drained periodicallyDrill Air receiver not testedDrill Air receiver safety valve defective/set very highDrill area on gradientDrill area unevenDrill Chocks not provided in compressorDrill Compressor too noisyDrill Defective or insufficient fan guard in compressorDrill Defective valve control system at compressorDrill Defective valve control system at drillDrill Delivery pressure higher than hammer pressureDrill Direction of Drill hole in correctDrill Hammer worn out shell resulting in jammingDrill holes not being flushed properly result towDrill Hose clamp not strong enoughDrill Hose just short and stretchedDrill Hose pipe rating is lower than air pressure

Drilling 1

Drill hoses aged and bulging

Drill hoses leaky

Drill hoses not secured

Drill Improper setting of pressure

Drill Improper towing arrangement for compressor

Drill level jacks defective

Drill lube oil leaky

Drill parking parallel to face

Drill Poor quality hose pipe

Drill Rod centraliser is badly worn out

Drill Storing of oil etc in compressorDrill string threads worn out

Drill Too heavy inclination and less than bench height

Drill Too long drill hosesDrill Too many out lets from compressor in useDrilling above undercutDrilling below over hang

Drilling 2

DumpDump not inspected for safety at the start of shiftDump tow chain etc not providedDump against general wind directionDump boulders rolling down to agricultural land near towDump drainage ineffectiveDump embankment of insufficient heightDump likely to slide and block natural water courseDump not graded against dump directionDump toe too close to inhabitation/just beyond natural angle of reposeDump too many trucks reporting crowdedDump seepage of ground water from belowDump poor illuminationDump floor too slushyDump floor too dusty

Work shop not equipped Work shop crane gantry not designed /Max permissible load not knownWork shop height too muchWork shop height lowWork shop illumination improperWork shop not equipped with over head crane gantryWork shop not protected from dustWork shop operators not trained in pulley block useWork shop operators not trained in pulley block useWork shop operators pulley block linking chains poor quality/weldedWork shop pulley block D shackles small/no proper bolt/welded, threads worn outWork shop pulley block area too many people aroundWork shop pulley block chains weldedWork shop pulley block hooks does not have auto lockWork shop trusses weakWork shop vertical span distance more Workshop floor too oily

Workshop 1

Workshop gantry trolley rollers worn out

Workshop grease, oil , cotton waste kept close to welding

Workshop width not designed for truck

Workshop floor too smooth

Workshop floor water/oil stagnating

Work shop single entrance and no exit

Work shop no fire extinguisher

Work shop extinguisher in sufficient

Work shop fire extinguisher incorrectly positioned

Work shop fire extinguisher not charged

Work shop pulley block area width narrow

Workshop tool room house keeping poor

Workshop tools not inspected for defects/replaced

Workshop tools of poor quality

Workshop tools spanners welded/bent

Workshop tools misuse of tools

Work shop fasteners not properly marked and kept

Workshop 2