Isolation / Lockout of ROM bins (Dump Hoppers)

[MJTaylor]

G'day,

I work at an open cut coal mine. We are currently looking for ways to isolate / lock out our ROM bins (Dump hoppers) on Plant Maintenance days, when we may have people working in the hoppers and we don't want trucks to dump in them. Does anyone have any experience from their operating sites on effective lockout of such bins? Currently we use plastic barriers (similar to those used during road work) across the access to the bin, but these are very small compared to the 240T haul trucks that dump in the bins. Ideas we are considering include:
- Flashing lights (but how does the guy in the bin know if the battery has failed and the light stops working?)
- Parking Vehicles in front of the bins (vehicles not always currently available)
- Alarm in Truck Cab activated by proximity to ROM bin (so if truck approached within say 100m an alarm sounds)

Any other ideas / experiences / suggestions?

Thank you.

 

[nnjunger]

One of the procedures we used at a mine I worked at was the flashing light. However, we approached it from another side. We said that the light had to flash in order for it to be safe for the truck to dump. That way, any failure in the circuit would stop the light, thereby telling the truck driver not to dump until the situation had been remidied. It acted like a failsafe for us. However, I would still like some kind of physical barrier, but I am not sure what would be feasible.

 

[smckennz]

We use light and tape.
Green light when ROM bin can be loaded. No green, no load.

Tape when working in bin and also cone off access road to bin.
However we have only two ROM bins. I would imagine the problem to worsen with the number of bins.

A physical barrier stronger that the haul truck appears the best solution. Perhaps you could build a largish (3m) berm in front of the bin.

Cheers

Steve

 

[Backfill]

Good question, good discussions.

The mines I've worked at have successfully used:
1. Failsafe light setup like nnjunger noted.
2. Barricade tape, or better yet, the polyethylene barrier fences, in whatever color is most eye-catching. They are light and can be rolled out easily, using either temporary or permanent fence posts/fixtures. Two are better than one, spaced about two haul truck lengths apart (at least on introduction and at night).
3. Park a light plant in the entry. A little spendy if it gets backed over, but it's a tough one to miss.
4. Along those lines, don't the mechanics have a vehicle? When they do, it should be parked to obstruct haul trucks. Make 3 and/or 4 part of the normal procedure. There always should be a loader, service truck, water truck, grader or something which can be parked to protect the maintenance crew.
5. K-rails (jersey barriers), especially well painted or flagged, can be set and removed quickly.
6. Establish a procedure where the final load before maintenance is dumped short, obstructing access. That may be the most assured method.
7. The proximity alarm is good for both maintenance and normal operation. Simply prudent, and you may have your dust suppression already set up on proximity switches.

Good luck, be safe