Contractor Worksheet Underground Fires Major Hazard Standard

Transcription

1 WMC Environment, Health & Safety Management System Worksheet Major Hazard Standard MHS-02 DocsOpen Ref: 57267, 17/10/2001 Uncontrolled copy check web for latest revision Revision Reviewed Description of Changes Date Approved 1 A Barfield Revised 17/10/2001 P Plavina 0 First Issue 12/07/2000 K Thomas WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.

2 CONTENTS 1 Purpose 1 2 Overview of the Contract Worksheet 1 3 Completion of the Worksheet 1 1 Purpose This document is designed to assist any person responsible for scoping a Contract to define what is required of a potential contractor to enable them to comply with the Standard SAF- MHS-02. In each of these areas the following are to be checked: Does the item need to be actioned by the? What is the timing of this action? Are there any further comments/issues to be noted in relation to the item? 2 Overview of the Contract Worksheet There are 12 areas addressed by the audit document: Fire Control and Management Maintenance Requirements for Mine and Infrastructure Design Personnel and Training Flammable Materials Requirements for Underground Mobile Equipment Requirements for Fixed Mechanical Installations Requirements for Fixed Electrical Installations Requirements for Fixed Air Compressor Installations Requirements for Workshops Crib rooms, Refuge chambers and Underground Toilets Requirements for Operation and Maintenance Procedures. 3 Completion of the Worksheet This worksheet is to be completed by the person responsible for preparing the scope of the contract. The exercise is best done with the assistance of a small team who possess the skills and experience to address the issues raised. The skills should include equipment selection, purchasing and maintenance; risk assessment; design and operation; and a thorough understanding of the application of the Standard. When this exercise has been completed all identified requirements are to be referenced in the tendering information and formal contract documents. SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 1 of 19

3 Person Completing Worksheet: Date: Person Completing Contract Documents: Brief Scope of Contract: Date: Comments: SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 2 of 19

4 Fire Control and Management 1 1 The site shall have a Fire Control Plan (FCP) 2 1 The plan shall be developed through a process of risk assessment 3 1 The plan shall be used for day-to-day management of fire risks 4 1 The plan shall explain the fire risks present in a mine and the methods by which the risks are managed 5 1 The plan shall at the least, address the requirements outlined in the Standard SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 3 of 19

5 Maintenance 6 2 There shall be a maintenance system that ensures the continuing safety of all underground equipment 7 The system shall establish standards of acceptable equipment condition and performance 8 2 The system shall detect and prevent the deterioration of equipment 10 2 The system shall store and manage maintenance information 11 2 The system shall report on equipment and maintenance management performance? SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 4 of 19

6 Requirements for Mine and Infrastructure Design The flammable materials and fluids stores shall be: in accordance with the appropriate standards constructed from non-flammable materials The flammable materials and fluids stores shall be: separated from possible ignition sources The flammable materials and fluids stores shall be: located away from collision hazards Fixed fuel oil transfer systems and underground fuel depots shall be: capable of being physically isolated in the event of a fire There shall be sufficient means to extinguish any fire that could occur in the mine A smoke-monitoring system shall be provided where a potential fire source exists near an intake airshaft SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 5 of 19

7 Personnel and Training 18 4 All underground personnel shall be competent for first response to fire 19 4 Only competent personnel shall handle flammable gases 20 4 Only competent persons shall use hot work equipment 21 4 The competency requirements for underground mobile equipment (UGME) operators shall include awareness of the types of fires and the methods used to control and fight fires 22 4 Fixed equipment operator training shall include the hazards related to overloading electrical systems SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 6 of 19

8 Flammable Materials There shall be a site policy where fire resistant materials are used in preference to flammable materials 24 All vee belts shall be fire resistant Flammable materials shall be stored: away from heat or ignition sources clear of lighting with no smoking signs displayed Flammable materials shall be stored in minimum quantities Electrical switchboards shall be located away from flammable materials or tyres stores The hot work permit system shall disallow hot work in or near stores which contain flammable materials gases or fluids The transport vehicles for flammable liquids shall be appropriate for the task Only purpose-built containers that prevent spillage shall be used to transport flammable liquids underground and they shall have clear and easily understood labels Flammable gas cylinders shall be: transported in accordance with AS 2030 transported so that no part projects over the vehicles extremity transported with the cylinder turned off Decanting of flammable gas cylinders shall be prohibited underground SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 7 of 19

9 Flammable gas cylinders shall be: separated from oxygen bottles by: a distance of at least 3 m, or a steel plate barrier at least the height of the flammable gas bottles next to the oxygen bottles secured so that they cannot fall over bottles of acetylene shall be stored in an upright position Flammable gas cylinders shall be: provided with non key operated valves fitted with flashback arresters on oxy-acetylene equipment The requirements for flammable gases shall be applied to oxygen cylinders Proper receptacles that prevent ignition sources contacting underground rubbish shall be located in workshops etc. The site shall have housekeeping procedures There shall be a sealed waste oil disposal system Tyre stores shall not be near parking areas Audits of housekeeping standards of all stored flammable materials and gases shall be conducted at least monthly and the audit results recorded Flammable material, gases and fluids stores that have a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection Flammable material, gases and fluids stores that have a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway Bulk fuel storage and tyre stores shall have an automatic fire suppression system, which is connected to the mine alarm system The bulk fuel storage and tyre stores fire suppression system shall have the capability of manual operation at the storage inlet At least 2 portable fire extinguishers shall be located close to main storage locations of flammable materials, on the intake airway side SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 8 of 19

10 Requirements for Underground Mobile Equipment (UGME) Equipment surfaces onto which flammable liquids could spray shall operate at temperatures less than 300ºC Flammable liquids or gases required for mobile equipment shall have autoignition temperatures greater than 350ºC Hoses shall be routed so that in the event of a burst or leaking hose, flammable liquid cannot contact a hot surface or Where routing away from hot surfaces cannot occur, all hoses shall be securely clamped and shielded so that in the event of a burst or leaking hose, flammable liquid cannot contact a hot surface There shall be engine control systems designed so that if a fault occurs which could lead to an engine fire the engine stops The engine control system that stops the engine in the event of a fire shall stop the fuel The engine control system that stops the engine in the event of a fire shall activate the fire suppression system All electrical systems shall be designed to AS Electrical systems that derive power from diesel engine alternators or batteries shall be designed to AS An automatic means shall be provided to disconnect power from the battery to the starter motor to protect against short circuits Jump-starting systems shall be purpose-designed for all electrical start equipment Where cables and hoses are to pass through bulkheads, they shall have either: rubber grommets fitted, or bulkhead connections to which the cables and hoses are attached All UGME, except for light vehicles, shall have: enclosed brake systems, or where open discs are installed, residual pressure monitoring and fire resistant brake hoses SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 9 of 19

11 All UGME except for light vehicles shall have sealed fuelling systems There shall be a system in place to: predict injection pipe failures change the pipes before the predicted failure Gauges and warning lights in the operator s cab shall monitor the temperature of the automatic transmission units on LHDs and earth moving trucks The cooling systems and engine shut down systems of UGME shall be monitored and include the use of warning lights for critical conditions Compressors used on UGME as part of the braking system shall be fitted with temperature monitoring which provides an audible and a visual warning at high temperature Compressors used on UGME for service air shall be provided with temperature monitoring that shuts the power source off at high temperature An automatic fire detection and suppression system shall be installed in the engine bay of each UGME The system shall cover air compressors that supply air to the brake system Two appropriately sized portable fire fighting extinguishers shall be installed on the equipment: All UGME shall have at least 2 exits from any operator cab that take into account probable fire locations Any remotely controlled equipment shall be fitted with remote-control activation of the fire suppression system SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 10 of 19

12 Requirements for Fixed Mechanical Installations All conveyor belts and skirting shall be fire resistant Fluid couplings shall not be used on conveyors Idler bearings on conveyors shall be sealed There shall be condition monitoring on conveyor systems for misalignment, slip, over-speed, overheating and blockages, all of which trip the belt Where ventilation fans are driven by vee belts, they shall be fire resistant Electrical protection against earth leakage and overload shall be provided There shall be condition monitoring on all belt driven equipment for belt slip detection Fixed equipment condition monitoring systems shall be tested every three months Fixed equipment that has a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection Fixed equipment that has a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway Areas containing fixed equipment shall have appropriate and sufficient portable fire extinguishers located on the intake airway side of the area SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 11 of 19

13 Requirements for Fixed Electrical Installations The fixed electrical installation shall be designed to minimise the need for maintenance personnel to work on live apparatus Electrical equipment shall be located so that damage by impact from vehicles is minimised Electrical cables shall be located so that impact from vehicles is minimised Electrical transformer installations shall be designed to contain oil leaks i.e a bund large enough for the oil volume and a system in place to keep bund area clean Reflectors shall be attached to fixed electrical installations and cables to make them clearly visible to operators Equipment shall have signs in accordance with AS Fixed electrical equipment that has a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection Fixed electrical equipment that has a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway? Where fixed electrical installations are within fenced enclosures, portable fire extinguishers shall be located inside and outside of the fence, on the intake airway side of the area Only non-flammable sprays shall be used during electrical maintenance Electrical maintenance work shall be done only by competent, licensed personnel Modifications to an electrical system shall only take place with the approval of an electrical engineer Expected production-related adjustments to the electrical system (e.g. moving cables) shall only be done by a method approved by an electrical engineer/statutory appointed person SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 12 of 19

14 Requirements for Fixed Air Compressor Installations Compressors where possible shall be located on the surface Compressor condition monitoring shall cover external bearing temperature, discharge air temperature, overload, oil pressure and oil level This monitoring shall trip the compressor Fixed compressors that have a significant or high fire risk (see Section 1) shall have smoke detection Fixed compressors that have a significant or high fire risk (see Section 1) shall have an automatic fire suppression system or be vented to the return airway Where a compressor is driven by a diesel engine, the engine shall comply with the requirements of Section 5.3 SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 13 of 19

15 Requirements for Workshops There shall be minimal storage of oils, lubricants, fuel etc., in workshops Chemicals that can create heat or fumes shall be stored appropriately and separated from workshops There shall be separate locations, that comply with Appendix G, for welding and oxy-acetylene work There shall be daily checks and leak tests of flammable gas equipment Space heaters in underground workshops shall have a surface temperature less than 300 C Space heaters in underground workshops shall be positioned so that rags, paper and other flammable material do not lay on the heaters Smoke detectors shall be provided in offices and stores There shall be at least 2 clearly marked exits from the workshop Workshops that have a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection Workshops that have a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway Workshops shall be ventilated into the return airway SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 14 of 19

16 Crib Rooms Crib rooms shall be ventilated All internal fittings shall be made of fire-resistant materials Battery charge racks shall be located in a well ventilated area separate from the crib room No Smoking signs shall be displayed in the crib rooms There shall be 2 exits from each crib room, or if 2 exits cannot be provided, all electrical equipment or other heat sources located away from the single exit Two portable fire extinguishers shall be provided outside the crib room SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 15 of 19

17 Requirements for Operation and Maintenance Procedures The site shall have a fuelling procedure The site shall have a Hot Work Permit System that covers all work conducted outside the designated hot work area Workshop maintenance SWPs shall cover fire hazards The following shall be included in procedures for the day-to-day operation and maintenance of mobile and fixed equipment: the removal of excess flammable materials and excess oil from the equipment before it is operated daily services shall ensure that lubricant levels in mobile equipment are adequate Induction training shall include the requirement that where a machine develops a condition where heat or fuel sources may lead to a fire it shall be stopped and repaired before further operation It shall be a requirement for vehicles with flat tyres not to be operated or moved, except to the nearest safe location Procedures shall include a requirement that equipment shall not be left unattended within 20m of stored explosives Procedures shall include a requirement that: explosives transported on or in UGME shall be in purpose designed containers and located away from heat sources detonators transported on UGME shall be in purpose designed containers that are: impact and crush resistant lockable anti-static highly visible SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 16 of 19

18 Procedures shall include a requirement that for all underground main magazines: a portable fire extinguisher is located outside the magazine and a sign is located above the extinguisher stating it is for vehicle and rubbish fires only persons do not attempt to fight an explosives fire with portable extinguishers to be free of accumulated rubbish have receptacles for rubbish placed outside the magazine into which explosives are not to be disposed only charge-up or explosive transport vehicles enter the magazines There shall be a fixed fire suppression system of a water spray type conforming to the relevant Australian Standards Where there is no fixed fire suppression system of a water spray type conforming to the relevant Australian Standards the following shall apply: a risk assessment shall be conducted to examine the potential for a fire and its consequences and confirms no significant or high fire risk rubbish is cleared daily from the magazine to receptacles outside the magazine and the receptacles are checked for any loose explosives daily a permanent physical barrier prevents vehicle access to the explosive storage areas within the magazine, which is at least half the height of the tyre diameter of the largest vehicle to enter the magazine The maintenance plan shall require full discharge tests of automatic fire suppression systems at intervals that ensure continuing effectiveness The maintenance plan shall require full discharge tests of automatic fire suppression systems at intervals that ensure continuing effectiveness on remotely operated equipment, from the remote operating unit Fire suppression test results shall be recorded in the maintenance system An inspection and maintenance procedure shall be established to ensure the continuing effectiveness of fire hydrants, extinguishers and signs which advise of fire hazards SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 17 of 19

19 The pre-start checks of all mobile equipment shall include checking: for uncontrolled ignition sources and flammable materials that the exits from the operator cab are useable the fire suppression system for rocks that could cause ignition sources e.g. between tyres and in the engine compartment The 250-hour inspection on mobile equipment shall include the following: an inspection of all sources of ignition and all flammable materials an inspection of fire suppression systems Supervisors shall check for explosives on or near UGME using a planned inspection checklist The workshop coordinator/foreman and individuals shall monitor work, to ensure it is done in accordance with Standard Work Procedures Daily inspections of fixed equipment shall include a check for ignition and flammable sources The site shall have procedures for the underground transport of bulk fuel by vehicle and/or fuel transfer by pipe SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No Page 18 of 19