The NSW Resources Regulator has reported an incident where a worker’s arm became caught in the tail pulley on the main drive of a screening plant belt. The worker removed a guard to view the belt tracking and put his hand in to remove a rock.The machine was at idle when the incident occurred.
NSW Resources Regulator have recently published an Investigation Information Release about a similar incident.
Operator serious injured after entered no-go area
Rock fall hits employee during ground support activity
The similar incident was occurred in May 2020 in Moolarben Coal Operations – Coal Handling and Processing Plant.
A worker observed that the belt on belt press filter 3 (‘the filter’) was out of alignment with a rotating drum. The worker stated that the belt had lost alignment because the hydraulic air lines servicing the filter’s tracking drum and tracking limit switch had become separated, resulting in a loss of air pressure to these components. The worker opened several doors in the guarding around the filter, using a key that he was authorised to use. The worker requested assistance from his supervisor by radio and began reconnecting the air supply.
The worker restored air pressure to the above components. He believed that the tracking drum would straighten the misaligned belt as it rotated. However, the tracking limit switch on the filter was designed to stop the plant from operating when a metal prong referred to as a ‘cats’ whisker’ contacted a misaligned belt. In order to override this function and allow the tracking drum to continue to turn and align the belt, the worker removed the ‘cat’s whisker’ by disconnecting it from the limit switch.
The worker was moving towards a rotating drum located in an area where the guarding had been opened. He stated that he lost balance and reached out to what he thought was part of a fixed structure adjacent to the drum. His left forearm was caught between the belt and the rotating drum. The drum had rotated approximately 135 degrees, when the supervisor arrived in response to the worker’s earlier radio message. The supervisor and another staff member activated the filter’s emergency stop and reversed the drum to release the worker’s arm.
The worker was airlifted to John Hunter Hospital where he underwent surgery for arm and wrist fractures.
NSW Resources Regulator stated: Entanglement between moving parts is a foreseeable risk. Mine operators are reminded of their duty to identify hazards and manage risks to health and safety associated with the operation, maintenance and cleaning of plant.
Mine operators and workers must ensure that when guarding around plant is removed for maintenance or cleaning purposes, all energy sources are isolated. Consideration must be given to installing interlock devices that prevent unguarded plant from operating when risks are present. Guarding must be restored to its secured position before the plant resumes operation.
Where it is identified that guards must be removed to complete a particular task while the plant is in operation (i.e. when replacing belts on filters) , a risk assessment must be undertaken and additional controls implemented to ensure that risks are reduced as low as reasonably practicable.
Mine operators should review:
- Division 6 of Part 5.1 of the Work Health and Safety Regulation 2017, in particular clauses 208 and 210.
- SafeWork NSW – Code of Practice – Managing the risks of plant in the workplace.
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