Apprentice injured while maintaining mobile crusher

Mine Type

All mine types

Incident

A third year apprentice was assisting a plant operator and a mechanical tradesperson to maintain the internal wear plates of a mobile crusher hired from a contractor. When the apprentice dropped a tool onto the conveyor below, it was decided to run the conveyor to recover the tool.

The pendant controller was plugged into the machine, and the ignition switch for the onboard diesel motor was turned to the 'Run' position. The apprentice started to exit the interior of the crusher by walking along the crusher impactor rotor. The rotor appears to have turned, causing the apprentice to fall onto the impact zone wear plates within the crusher. The rotor struck him in the pelvic region causing multiple fractures.

Equipment

Terex Pegson 4242SR Mobile Tracked Impactor Crusher.

Hazard

Uncontrolled rotation of crusher rotor.

Cause

This incident is currently under investigation.

Comments

Investigations so far have highlighted the following:

• The Original Equipment Manufacture (OEM) operating and maintenance manuals were not provided to the user. Suppliers of plant and equipment have an obligation to provide the end user with the relevant OEM manuals.
• A risk assessment to identify hazards associated with operating and maintaining the crusher was not undertaken.
• The locking pin, used to prevent rotation of the crusher impactor rotor, was left on the truck that delivered the crusher.
• Critical safety procedures do not appear to have been covered during the two days of informal training provided by the supplier.
• The workers were unaware of the isolation procedure for the impact rotor, including the need to use the locking pin and to have the clutch disengaged.
• The site's general isolation and lock-out procedures were not followed.

Recommendations

• When taking ownership or hiring equipment, an appropriate equipment acceptance checklist must be used to ensure the equipment meets the site's relevant standards, and that OEM manuals, risk assessments and special safety devices are provided at the time of delivery.
• When introducing plant to a site, conduct a risk assessment covering operating and maintenance hazards and the plant's integration into the operating environment. When completing the risk assessment, reference all relevant manuals, as well as OEM or supplier risk assessments. This should be followed by an appropriate risk assessment for operational and maintenance tasks before undertaking specific tasks.
• Where the OEM specifies isolation or restraint devices - such as locking pins - ensure these devices are used and the maintenance workers are aware of the need to use them to control all potentially harmful energy sources.
• All employees involved in maintenance should be instructed in, and be aware of, the specific safeguards necessary for safe maintenance.
• Regularly monitor isolation practices to ensure they are effective and comply with the isolation procedures for the mine.
• Supervision of workers should be appropriate for their level of knowledge, skills and experience.

Authorised by Phil Goode - Regional Inspector of Mines, Southern

Contact: minesafetyandhealth@dnrm.qld.gov.au

Issued by Queensland Department of Mines and Energy