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Topic One:
Learning Outcomes:
• Identify typical hazards relating to the operation and
maintenance of grinding mills.
• Recognize risks associated with specific tasks.
• Use hazardous materials safely.
• Apply recommend control measures.
• Follow safe working procedures.
Grinding Mill Safety
Off line:
On line:
• During Operation
• Work Environment
• High-Pressure Hydraulics
Live and Stored Energy
Inside the Mill
Rotating the mill
Confined Space
Work at Height
Hot Work
Solvents and Adhesives
Grinding Mill Safety
During Operation
Hazards include:
• Large, powerful rotating components.
• Electrical energy.
• Pressurized oil and water systems.
Controls include:
• Keep within designated walk areas
and outside of protective barricading.
• Do not reach behind or remove safety guards.
• Do not work on running equipment, except
for specific inspections and adjustments.
• Stop, isolate, lock and tag if work is required
to be carried out.
Grinding Mill Safety
Work Environment
Hazards include:
• Excessive mill noise.
• Dust exposure.
• Poor lighting inside mill.
• Water / electricity interaction
Dust collector
Work Environment
Controls include:
• Use hearing protection
when working around an operating
mill or during noisy maintenance work.
• Due to normal ore transport operation,
there is dust accumulated in the
The risk is mitigated by using
a dust suppression system and respirators.
• Ensure sufficient lighting is provided
when working inside the mill.
• Keep electrical cables clear of water in the
mill area.
Grinding Mill Safety
High-Pressure Hydraulics
Hazards include:
• Able to inject oil through the skin.
Controls include:
• Ensure all hydraulic pressure is released
before attempting any work on the system.
• Do not check leaks with bare hands.
• Stay out of the line of fire.
• Use protective clothing and equipment.
Grinding Mill Safety
High-Pressure Hydraulics
Hazards include:
• Able to inject oil through the skin.
Controls include:
• Ensure all hydraulic pressure is released
before attempting any work on the system.
• Do not check leaks with bare hands.
• Stay out of the line of fire.
• Use protective clothing and equipment.
Photographs showing the innocuous appearance of a fluid injection
wound and the extent of the surgery needed to treat it.
During an Equipment Shutdown
Lock out/tag out all energy sources
• The Electric Panels, MCCs and switchboards need to be
de-energized during maintenance activities.
• When this happens, you need to communicate with a large number
of people involved in the maintenance of different disciplines.
Lock out/tag out tags
While the System is Down
Lock out/tag out:
Before starting any shutdown maintenance make sure all the
mechanical and electrical forces are restrained. Eg. Lock out/
tag out motors, and release hydraulic pressure.
Grinding Mill Safety
Live and Stored Energy
Hazards include:
Uncontrolled mill movement.
Unexpected mill start-up.
High pressure lines.
Controls include:
• Ensure the mill is stable, brake activated and the
mill isolated before entering.
• Apply lock and tag procedures before commencing
any work.
• Test for dead and check all pressures are released.
Cary out risk assessment
Grinding Mill Safety
Inside the Mill
Hazards include:
• Falling rocks and other material from above.
• Slippery and uneven surfaces
• Confined space
• Heavy manual lifting
Controls include:
• Ensure the mill is stable, brake activated and
the mill isolated before entering.
• Check for material hang-up before entering.
• Follow confined space entry procedures.
• Use lifting and liner handling tools provided.
Grinding Mill Safety
Rotating the mill
During some maintenance the mill will require
to be repositioned.
Hazards include:
• Damage to mill bearings.
• Personal injury.
Controls include:
• Ensure all personnel and equipment are
clear of the mill.
• Check braking system is operational before
• Ensure the hydraulic system is operating
during inching. Never rotate the mill on dry
bearings. Run the lubrication system while
the mill is rotated.
• Make sure to fully engage inching drive
before rotating mill with load.
Grinding Mill Safety
Confined Space
Work inside the mill can create hazards
due to the confined space environment.
Hazards include:
• Flammable products.
• Toxic fumes and gasses.
• Restricted work area.
Controls include:
• Follow confined space entry procedures.
• Carry out atmospheric tests for flammable or
poisonous gasses.
• Ensure you have an Oxygen gas detector and
adequate ventilation.
• Use respirators as required.
• Never enter a confined space that has an
unsafe atmosphere.
The Mill is considered a confined
Grinding Mill Safety
Work at Height
Some work may be required to be carried out above
installed platforms and work areas.
Hazards include:
• Unstable, slippery or uneven footing.
• Risk of falling – people, tools and components.
Controls include:
• Carry out risk assessment before attempting
to perform the job.
• Install scaffolding or use suitable elevated
work platforms.
• Restrict access to the area below.
• Use fall arrest equipment.
Cary out risk assessment
Work at Height
• Scaffolds must be rigid
and structurally sufficient
to support their own weight,
plus four times the maximum
intended load.
• Scaffolds must be erected on solid footings.
• Scaffolds must be equipped with guardrails
consisting of handrails, mid rails and toe boards.
• Access between levels must be by internal ladders
or stairs with proper guardrails.
Safety Harness – Do you know your equipment?
Is the harness dirty, damaged,
modified, contain any visible cuts
or marks? Look and feel on
webbing, connection points,
assembly joints, buckles etc.
Have you spent 5 min. reading
the instruction?
D-ring correctly adjusted
in the middle of the back
between shoulder blades.
If not a fall can result in
serious damage to the
Adjust upper part for a
snug fit by adjusting the
Adjust lower part for a
snug fit by adjusting the
webbing. Tighten to the
point where a couple of
fingers fit comfortably.
• Scaffold platforms must be tightly planked with scaffold plank-grade material or
the equivalent.
• Scaffolds must be at least 3 m (10 ft) from electric power lines at all times.
• Scaffolding may only be erected, moved, dismantled and/ or altered under the
supervision of a qualified, competent person.
• The rigging on suspension scaffolds must be inspected by a competent person
before the start of each shift, and after any occurrence that could affect the
structural integrity of the scaffold, e.g., high winds or heavy rains.
There are different models of harness
available on the market. In FLSmidth
we require a Full-body Harness for site
Norm or Standard identification
including next inspection date.
Scaffold inspection tags
Total fall distance must be taken into consideration when using lanyards.
What is the total length of the fall including your own height?
On top of this remember to add a safety factor of 1 m. What is the distance to nearest obstacle in case
you fall? Will your setup allow you to remain suspended?
Total fall distance = length of lanyard + absorber extension + height of person + safety factor
Swing radius must be taken into consideration in order to avoid injuries from collision with obstacles.
Make an assessment of your anchor point in order to avoid collision with obstacles.
Speaking of anchor points; to be safe an anchor point must be able to withstand a minimum of 1200 kg!
Lanyards: There are different types of lanyards for different purposes.
Lanyards without shock absorbers are suitable for areas where it is
necessary to prevent a fall by limiting working radius. This type of
lanyard would prevent a person reaching the boarder which could result
in a fall.
Lanyards with shock absorbers are suitable for areas where a risk of
fall is present and cannot be prevented by other means. Depending on
the type of fall the fall itself may be several meters. (see next slide for
Self-retracting lifelines are suitable for areas where a fall should be
kept at an absolute minimum distance. The system works like the
seatbelt in a car which limits the fall to a matter of a few cm.
Lanyards without shock
Lanyards with shock
Grinding Mill Safety
Hot Work
Sometimes it will be necessary to use oxy cutting
or welding equipment.
Hazards include:
• Fire.
• Flying sparks and molten metal.
• Arc flash.
Controls include:
• Know the location of fire fighting equipment.
• Follow site hot work procedures.
• Protect exposure around and under the mill
from flying or falling hot metal.
• Erect screens and barricades to protect others
from arc flashes and flying hot metal.
Welding and torch cutting:
Make sure that such activities can be
carried out safely and without the chance
of contacting flammable materials,
lubrication or hydraulic oil, especially if it is
under pressure.
Grinding Mill Safety
Many components will require lifting devices to
be used during maintenance.
Hazards include:
• Lifting weights above rating of lifting
• Incorrect slinging positions.
• Crushing injuries or equipment damage.
Controls include:
• Use only lifting equipment capable of and
designed for the loads being lifted.
• Refer to the FLSmidth Installation, Operation
and Maintenance (IOM) manual for lift weights
and sling positions.
• Plan the lifts so they can be done safely
• Keep others clear of the lift area.
Solvents and Adhesives
Replacing the rubber lining in the mill requires
the use of solvents and adhesives which may be
Hazards include:
• Flammability.
• Toxic fumes.
• Poisoning.
Controls include:
• Refer to manufacturers safety instructions.
• Use recommended personal protective
• Follow confined space procedures.
• Maintain good ventilation.
Ventilation system
Hazards include:
• Restricted work areas.
• Material and water spillage.
• Items falling from upper levels.
Controls include:
• Keep all walk and work areas clean and tidy.
• Clean up any material, water or oil spills promptly.
• If working on upper levels, barricade the area below
on lower levels.
Good housekeeping is essential for a safe working environment.
Spillages should be cleaned up as soon as possible, since can
result in slips, trips and falls.
Personal Protective Equipment (PPE)
Safety depends on you!
• Check your PPE.
• Use it in the correct manner and at all times.
• Get the right permits and authorizations to perform any maintenance activity.
• Recognize potential safety hazards and correct them.
Never perform a task that you consider unsafe.
If you can not identify a safe way to perform the task,
ask your supervisor and together evaluate the most
appropriate procedure.