Lesson 3 – Underground Compactors

The safe use of compactors, equipment and tools

Responsibility

• The Competent Person appointed in terms of Regulation 2.13.1 (or his delegates) shall ensure that the use of any Compactor is carried out in accordance with this SOP and that the Compactor is in good operational condition and shall not endanger the life of persons.

 

Appointments

• Compactor Operators (at BML) shall only be operated by authorized persons, provided such persons meet the following requirements;

–That person is trained, assessed, found competent and authorized in writing by the responsible Engineer (or his delegate), and

–That person is appointed in writing by his/her supervisor to operate a Compactor Machine. Such appointment must detail their duties, responsibilities, limitations and areas of operation.

 

Compactor maintenance

• The maintenance conducted on Compactor Machines is regulated by a maintenance plan, which combines the set-out OEM maintenance plan (as basis for all services), together with what can practically be implemented and maintained.
• Only persons that have been trained and found competent and appointed by the Engineer shall be allowed to perform maintenance functions on the Compactors.
• Pre-use inspections (Checklist) must be conducted before putting any Compactors in operation, to ensure that the machine is in sound condition and that all safety and warning devices are in good working order.

 

General safety practices

• The area whereby the Compactor are used needs to be declared as a safe area by a Competent A person or Miner.
• All Compactors and related equipment must be used for the purpose that it was intended for, and within its designed capacity;
• The Operator must ensure that he has a clear view of the area he is going to operate in;
• Good housekeeping must be maintained in all workshops, repair bays and garages where Compactors are kept;
• Compactors will not operate in the Main Decline situated at 60 Level at Fairview
• Compactors will not be left idling for longer than necessary. If the Operator is to leave his machine for a considerable length of time, he should switch off, remove the ignition key and make sure the vehicle cannot move by itself before he leaves such compactor. Operators must adhere to the parking procedure as mentioned in COP 6 A Under no circumstances may the engine be allowed to idle longer than 5 min accept when the Artisan is testing the machine.

 

Lock- out

• Once the Compactor has stopped work or completed activities the starting handle must be removed for Lock Out purposes

 

Accidents

• Any accident/incident must be reported to the immediate Supervisor without delay. The appropriate accident/incident procedure will apply.

 

Protection of driver/operator or other persons

 

Section 23.1(a) – Employees’ right to leave dangerous working place.

• The employee has the right to leave any working place whenever circumstances arise at that working place which, with reasonable justification, appear to that employee to pose a serious danger to the health or safety of that employee; or the health and safety representative responsible for that working place directs that employee to leave that working place.

 

Inadvertent movement (Before you leave the Compactor unattended)

• All Compactors will be parked as per item 8.15.1(o) of COP 6A, COMPACTOR will be parked or stopped in a safe flat area

 

Parking.

• Since a compactor is not usually fully extracted to a workshop between shifts, ii is the operator’s responsibility to ensure that the compactor is parked at a safe place and barricaded as such to clearly indicate its position to other travelling TMMs. It should also be parked well outside the blasting zone.

–The compactor will never be parked in the way of other traffic, and will never be parked on an inclination.

–Ensure that the compactor controls are in neutral.

–Shut down the engine.

–Remove the starting handle and keep it in a safe place.

–NEVER leave the engine running if the TMM is not being used.

• and if applicable, in conjunction with the lock-out procedures as mentioned in COP25. (In this case for the Compactor is to remove the Dead Man’ Handle)
• Except for the pedestrian compactor and the E15 Tractors, all other TMM’s are equipped with a shut-down solenoid that cuts off the engine and effectively applies the fail-safe brakes within 5 seconds of the operator leaving his seat.

 

Inadvertently running out of control

• All Compactors shall utilize all braking systems including the service, park and emergency brake devices to bring the vehicle or machine to a controlled stop.

 

Positioning of light fitted to underground

• Compactors will not be fitted with any lights due to its design.

 

Pedestrian Compactors

• All Sides : Yellow/Orange
• Flag-Pole : Triple Stripe (Red+ Yellow+ Red)
• Compactors will also be provided with an additional “flag-pole”-reflector that will be 1.3m high, and shall be positioned on top of the vehicle when not in use.
• No entry signs to be placed on both sides of the compactor where it is in operation.

 

Maintenance

 

Compactor’s maintenance plan

• The maintenance conducted on Compactors machines is regulated by a maintenance plan, which combines the set-out OEM maintenance plan (as basis for all services), together with what can practically be implemented and maintained.
• The following information has been used to formulate the Maintenance Plan at Barberton Mines Limited.

–The OEM’s Operation and Maintenance Instructions which forms the basis for each Compactor’s service plan,

–The general working conditions associated with Humidity, Dust and Temperature.

–The average working hours of each Compactor,

• The above mentioned information has been used with the general understanding;

–That no service-items will be longer in operation than it was intended to, by the TMM’s OEM,

–That intervals-of-service can be shortened, so as to combine services together into a more practical execution thereof, and

–Pre-use inspections (Checklist) must be conducted before putting any Compactor in operation, to ensure that the vehicle is in sound condition and that all safety and warning devices are in good working order;

 

Compactor’s maintenance plan

• Maintenance schedules take place as prescribed by the Original Equipment Manufacturer or revised by the Responsible Engineer.
• All Compactors Checklists will have a list of Safety, and Safety Critical Components and/or related issues, which will be checked and inspected by the operator and/or artisan. These checklists will be stored by the TMM Foreman, for a minimum period of three months.
• If a deficiency that falls under a ‘No Go’ defect (any safety devices) is identified, such machine shall not be used until the defect is fixed. The responsible supervisor, Artisan or Mechanic shall over inspect and repair the defect.
• All rigging on TMMs will be done in accordance to SOP31 (Transport and Handling of Heavy Equipment), and SOP41 (Lifting Equipment).

 

Health and safety standards

 

Operators fatigue

• Operators should take a break not less than ten minutes after every two hours to reduce operator fatigue. The frequency of such rests could be altered according to specific environmental conditions;
• Operators are not allowed to work more than the recommended hours as stipulated in the Basic Conditions of Employment Act; and
• No work to be done on Compactors in unventilated / poorly ventilated working places. Accumulation of gas may lead to incapacitation of operator, increase the risk of heat related illnesses and exposure to airborne pollutants. A safe declaration needs to be done before entry can be done by an Competent A person, miner or Shift Boss.

 

Ergonomics

• Posture

–The operator has no adequate protection from overhead physical hazards such as falling objects and roof mounted structures;

–Confined spaces limit the movement ability of the operator.

• Design, control and maintenance of noise control systems to which the Compactor operator and the immediate environment are exposed.

–Noise control system table;

–If required, personnel are provided with hearing protection, which is freely available, and the use thereof is monitored on a regular basis through the Hearing Conservation Program; and

–Noise levels are monitored continuously as scheduled by environmental department.

 

Acknowledgement of acceptance and appointments

 

The mechanical foreman is responsible to ensure the following:

• Communicate all safety procedures to maintenance staff
• Communicate all operating procedures to maintenance staff.
• Communicate all maintenance procedures to maintenance staff.
• Maintain an environment that will contribute to maximum equipment availability.
• Ensure that Safety and Maintenance Procedures are adhered to at all times.
• Ensure no removing/tampering and or disconnecting of any safety device.
• Ensure that electrical and mechanical maintenance is done

 

Artisan’s responsibilities:

• Communicate all Safety Procedures to his/her aide and Assistants.
• Communicate the Maintenance Procedures to his/her aid and Assistants.
• Maintain the Compactor to the required availability level and to ensure all safety standards.
• Carry out maintenance as per maintenance procedures.
• Ensure that machines are maintained in accordance to the planned maintenance schedules.
• Report to the Site Manager/Mechanical Foreman any incidents on the mine relating to mobile machines which could result in an injury to persons or loss of availability.
• Ensure daily checklists are completed and to report any defects or damage to Maintenance Supervisor.

 

Shift supervisor responsibility:

• Ensure that all personnel in the underground workings have a sound knowledge of the hazards associated with Compactors.
• Communicate safety precautions during safety meetings.
• Test personnel in working place at least once a month on fire drills and Emergency Procedures.
• (Record in notebook).
• While conducting an early shift, he/she will ensure compliance with all procedures on Stopping of Machines (record in notebook).
• Ensure daily checklists are completed and report any defects or damage to Mine Overseer.
• Faulty equipment indicated as “No Go” may not be operated.
• Ensure that the area where loading takes place at the start of each shift is examined by the Miner and periodically during the shift. (Over inspections to be recorded in Shift Boss’ note book).
• To wear reflective vests or luminous markings on their overalls.

 

Operator responsibility:

• Adhere to the Standard Operating Procedure governing the use of Compactors at all times.
• To report any defects to the Shift Boss and Maintenance Personnel immediately.
• Conduct “Daily Checklists” and report any defects or damage to Shift Boss and Maintenance personnel
• Clean and lubricate the machine thoroughly at the start of the shift
• All Compactor Operators are issued with self-rescue packs which they are required to wear at all times.
• Faulty equipment indicated as “No Go” may not be operated

 

Design of excavations and roadways

• All roads must be of such dimensions as to facilitate smooth operation without undue obstructions in the form of other structures. They must be compatible with operation and general sizes of the vehicles used. Each path must be kept as clean as possible to reduce the risk of skidding and tipping over. Oil and grease spillage must be kept to a minimum and objects must be removed from the path of vehicles;
• Specific restricted areas where Compactors are not allowed access to will be clearly demarcated. Such areas should be equipped with applicable safety devices in order to prevent any Compactor access to the area; and
• Specific Signs shall be placed whenever a Compactor is operating in a section to warn persons of the Compactor’s operation.

 

Operating rules

• No operation of underground TMM’s are allowed during blasting operations.
• (All Compactors shall be parked at the dedicated TMM workshop, or if that is not possible the Compactor shall be parked a safe distance from the blasting area and never in direct line-of sight of any blasting face.)
• Pre-Shift Inspection (Checklist) is conducted by the Operator. Every Operator/Driver of self-propelled mobile machine will do a pre use inspection of the equipment prior to using it.
• Checks to be carried out prior to starting up

 

General Checks and Safety

–Compactor ID

–Hour meter reading

–Check General Safety Conditions

–Check General Compactor Frame Parts for any defects

–Check the starting handle and condition

–Inspect and grease all greasing points

–Visually check Diesel level

–Visually check the Hydraulic Oil

–Visually check the Engine Oil

 

 

Operating rules

 

Safety Critical Checks

• Check Dead-Man-Switch (The forward/reverse handle must always return to neutral when released)
• Check arm and steering handle secured to main frame
• Check forward & reverse controls are secured and working well
• Check forward & reverse movement

 

Safety Critical

• Check Vibration function and operation

 

Parking in a safe area

• The Compactor will be parked or stopped in a safe flat area.
• Since a compactor is not usually fully extracted to a workshop between shifts, it is the operator’s responsibility to ensure that the compactor is parked at a safe place and barricaded as such to clearly indicate its position to other travelling TMMs. It should also be parked well outside the blasting zone.
• The compactor will never be parked in the way of other traffic, and will never be parked on an inclination.
• Ensure that the compactor controls are in neutral.
• Shut down the engine.
• Remove the starting handle and keep it in a safe place.
• NEVER leave the engine running if the TMM is not being used

 

Traffic rules and road signs

• Whenever a Compactor Operator becomes aware that pedestrians or other TMM’s are within close proximity of the Compactor he/she is operating, the following shall apply,

–the operator shall satisfy himself that such pedestrians or other TMM’s are aware of his location, and

–that the health and safety of such pedestrians and TMM’s are not in danger while he/she is operating the TMM.

 

General safety rules regarding interaction between pedestrians, cyclists and TMM‘s

• Pedestrians will not approach to within 20 meters of a stationary TMM unless the engine/motor of the TMM is turned off or the operator has given a clear signal that it is safe to pass.
• End Of Shift Procedures

–Park machine in a safe flat area, not blocking traffic, in a parking bay if it is available

–Apply park brake

–Select neutral

–Check all gauges and warning lights

–Shut engine down

–Remove key if provided

–Lock out machine

–Walk around machine to check for leaks and damages

–Record end of shift hour meter

–Complete and sign checklist at the (start and end of shift)

–Discuss with the operator who is coming on shift

–Checklist to be submitted to the production supervisor.

 

Procedure in case of fire

• Immediately upon noticing a fire the operator must: Stop the Compactor.
• Apply the park brake where applicable. Turn the engine/motor off.
• Remove the steering handle
• A portable fire extinguisher must be used in the event of a fire while taking up position in fresh air side. If the fire persists
• Make use of any nearby fire fighting equipment or water to extinguish the fire. Raise the alarm to enable persons to reach refuge bays.
• Activate self-rescuer if required.