Please read this before using presentation

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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
• ResourcesSafety_at_docep.wa.gov.au
• or visit
• www.docep.wa.gov.au/ResourcesSafety

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Toolbox presentation Classified plant
requirements for mining operations and
registering classified plant

• October 2007

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Introduction

• Are you confused and unfamiliar with classified
  plant?
• If you are then youre not alone!
• This presentation provides information on
• Resources Safetys requirements for registration
  of classified plant
• frequently asked questions relating to classified
  plant
• tips and rules of thumb when dealing with
  classified plant

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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

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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

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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

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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

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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)
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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

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Registration process cont.

• Elements that must be dealt with when making and
  reviewing applications
• Authorisation of applicant
• Assessment of plant
• Application preparation
• Application submission
• Review of application
• Issue of registration number

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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 doesnt have or hasnt included a copy
  of their authorisation letter from the Registered
  Manager or Principal Employer

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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

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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

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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

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What about hire and contractors 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

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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

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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

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5. Review of application

• Please remember that inspectors dont 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

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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 doesnt respond or the matter is
  not resolved over a period of time, the
  application may be sent back or filed

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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

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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

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Pressure equipment
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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

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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

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What pressure vessels are registrable?

• Pressure vessels categorised as hazard level A,
  B or C according to AS 4343
• Boilers

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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 youre 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

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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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Pressure equipment in summary and important tips
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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 gt150L
  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

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Things to check on pressure vessels

• 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

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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
  manufacturers 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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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

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Pressure relief valves (PRVs)

• 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

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Cranes
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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

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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?

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Hoists
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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

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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?

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Workboxes suspended from cranes
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What about man baskets attached to crane booms?

• Not deemed to be workboxes suspended from cranes
• Not required to be registered with Resources
  Safety

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Further information

• Go to Resources Safety website and look for
  classified plant www.docep.wa.gov.au/ResourcesSa
  fety
• 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
• ? ResourcesSafety_at_docep.wa.gov.au