Maintaining Safety Around Crushers

Maintaining Safety around Crushers and other processing equipment with proper guarding and work practices is an important OHS issue within the extractive industry. Below is an extract from the CMPA’S WORK SAFELY REFERENCE MANUAL regarding Fixed Plant – Crushers, Rock Boxes, Screens, Pugmills, Pumps and Cyclones.

A requirement of operating any mobile or fixed processing equipment is to ensure that the General Safety Checks are carried out prior to operation, during processing and at the end of production. (Refer to the Crushing / Screening Reporting and Inspection Book put together by the CPMA with assistance from members) This will ensure that the equipment is in a safe working order to operate.

Crushers and other processing equipment may start automatically or manually. Where equipment can start automatically whilst people are working on the plant, a pre start siren will sound and a flashing light in view of the personnel working will flash before the conveyor starts. This will give enough time for personnel to promptly stand clear before the conveyor operates.

Manually operated equipment must not be started until the Supervisor confirms everything is ready and the plant has been inspected to ensure people and plant are secured and prepared for the start.

Some controls include:

• Keep walk ways and access ways around crushers, pugmills and screens clear of debris to prevent tripping
• Always wear appropriate PPE including safety boots, respirators, dust masks, gloves, hard hat, eye and ear protection
• Always advise your Supervisor before commencing work on any crusher, screen, pugmill or cyclone
• Always isolate the equipment at the motor isolator switch and fit a ‘Danger Tag’ before commencing work
• Keep hands and feet clear of hydraulic rams and spring clusters during maintenance and operation
• Crusher blockages must be treated with extreme caution. Contact your Supervisor before attempting to unblock any equipment. See below : Checklist for Crusher Stoppages
• Do not attempt to clear blockages with crowbars whilst equipment is operating
• Never release trapped iron in crushers without your Supervisor’s approval
• Never remove any guards while equipment is running
• Never remove guards without your Supervisor’s approval
• Never operate equipment without all guards fitted
• Never work on pumps without your Supervisor’s approval
• Report any excessive or unusual emissions (i.e. dust, noise, vibrations, burn smells) to your Supervisor

CHECKLIST FOR CRUSHER STOPPAGES

1. BEFORE DOING ANYTHING contact you’re Supervisor and any other relevant persons (including the operator feeding the plant!)
2. Isolate the crusher to prevent it accidentally starting
3. Relieve any hydraulic pressure if necessary and you are trained to do so
4. If conveyors are not fitted with anti-rollback devices, take appropriate action
5. Establish whereabouts of all persons on site
6. Inspect:
   – Display panel and monitors supporting crusher to establish issue
   – Inside chute from above to ensure no foreign objects are lodged in crushing chamber
   – The crusher’s electrical and hydraulic warning devices
   – Motor drives and v-belts
   – Underneath crusher to ensure material has not built up or a foreign object has become jammed
   – Oil discharge or cracking of mainframe
7. Account for all persons on site and if safe to do so, remove isolation
   and restart crusher.

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