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Topic One: EQUIPMENT-SPECIFIC SAFETY GRINDING MILL SAFETY 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 Lifting Solvents and Adhesives Grinding Mill Safety On-line 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 On-line 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 environment. 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 On-line 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 On-line 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 Off-line Live and Stored Energy Hazards include: • • • • Uncontrolled mill movement. Unexpected mill start-up. Electrocution. 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 Off-line 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 Off-line 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 inching. • 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 Off-line ventilation 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 space! ventilation Grinding Mill Safety Off-line 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 • 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 body. Adjust upper part for a snug fit by adjusting the webbing. 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 use. 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 details) 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 absorbers Lanyards with shock absorbers Self-retracting lifeline Grinding Mill Safety Off-line 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 Off-line Lifting Many components will require lifting devices to be used during maintenance. Hazards include: • Lifting weights above rating of lifting equipment. • 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 harmful. Hazards include: • Flammability. • Toxic fumes. • Poisoning. Controls include: • Refer to manufacturers safety instructions. • Use recommended personal protective equipment. • Follow confined space procedures. • Maintain good ventilation. Ventilation system Housekeeping 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. DO NOT RISK YOUR AND YOUR COWORKER’S SAFETY! 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. Questions?