Transcript 2005 Mines Safety Roadshow

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:
[email protected]
or visit
www.docep.wa.gov.au/ResourcesSafety
Department of Consumer
and Employment Protection
Resources Safety
1
Toolbox presentation:
Classified plant requirements for
mining operations and registering
classified plant
October 2007
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
Department of Consumer
and Employment Protection
Resources Safety
3
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
Department of Consumer
and Employment Protection
Resources Safety
4
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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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The team
From left: Jim Farnworth (Karratha), Barry Evans (Kalgoorlie), Rod McFarlane
(Perth), Brett Boneham (Perth), Scott Kay (Perth), Dino Busuladzic (Perth)
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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Registration process
cont.
Elements that must be dealt with when making and
reviewing applications:
1. Authorisation of applicant
2. Assessment of plant
3. Application preparation
4. Application submission
5. Review of application
6. Issue of registration number
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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Pressure equipment
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
23
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
Department of Consumer
and Employment Protection
Resources Safety
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What pressure vessels are registrable?


Pressure vessels categorised as hazard level “A”, “B” or “C”
according to AS 4343
Boilers
Department of Consumer
and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
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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
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and Employment Protection
Resources Safety
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Pressure equipment in summary and important
tips
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and Employment Protection
Resources Safety
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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
Department of Consumer
and Employment Protection
Resources Safety
29
Things to check on pressure vessels
Department of Consumer
and Employment Protection

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
Resources Safety
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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
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and Employment Protection
Resources Safety
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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 as inspections, 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
Department of Consumer
and Employment Protection
Resources Safety
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Pressure relief valves (PRVs)
Department of Consumer
and Employment Protection

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
Resources Safety
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Cranes
Department of Consumer
and Employment Protection
Resources Safety
34
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
Department of Consumer
and Employment Protection
Resources Safety
35
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?
Department of Consumer
and Employment Protection
Resources Safety
36
Hoists
Department of Consumer
and Employment Protection
Resources Safety
37
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
Department of Consumer
and Employment Protection
Resources Safety
38
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?
Department of Consumer
and Employment Protection
Resources Safety
39
Workboxes suspended from cranes
Department of Consumer
and Employment Protection
Resources Safety
40
What about man baskets attached to crane
booms?

Not deemed to be workboxes
suspended from cranes

Not required to be registered
with Resources Safety
Department of Consumer
and Employment Protection
Resources Safety
41
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
 [email protected]
Department of Consumer
and Employment Protection
Resources Safety
42