ANNEXURE G: GENERIC OPERATIONAL AND MAINTENANCE PROCEDURES
(For information purposes)
| 1. |
The following is a series of technical solutions that shall be considered for addition in the mine’s action plans, as part of the COP, and/or operating standards associated with this COP including, but is not limited to, the following: |
| 1.1. |
Good housekeeping practices in refuelling bays. |
| 1.2. |
The safe operation of fuel transfer systems. |
| 1.3. |
The refuelling of vehicles, equipment and fixed plant. |
| 1.4. |
Fuel transfer between storage systems. |
| 1.5. |
Replacement or changing of fuel cells or storage tanks. |
| 1.6. |
The installation, location and maintenance of signage. |
| 1.7. |
Management of data pertaining to vehicle and equipment maintenance. |
| 1.8. |
Performing planned maintenance inspections and servicing of fuel transport and filling equipment. |
| 1.9. |
Report on equipment condition and maintenance effectiveness and standards. |
| 2. |
As part of the maintenance system, procedures should be implemented that incorporate the following to reduce fire risk: |
| 2.1. |
Daily equipment servicing should include the removal of excess flammable materials (e.g. oil, grease) from the equipment before it is operated. |
| 2.2. |
Maintenance work on equipment should include the removal of excess flammable materials (e.g. oil, grease) from the equipment before it is operated. |
| 2.3. |
Where an operator becomes aware that an equipment develops a condition where heat sources or fuel sources may lead to a fire, he/she must stop the machine immediately. These shall be rectified and repaired before further operation. This procedure should be included as part of the induction training Programme for engineering employees. |
| 2.4. |
Daily equipment pre-use inspection shall ensure that lubricant and coolant levels in mobile equipment and fixed plant are adequate. |
| 2.5. |
Any maintenance work undertaken involving the use of oxy-acetylene equipment shall be undertaken in a designated hot work areas or subject to a hot work permit. |
| 2.6. |
Injector lines shall be changed out at intervals as per OEM specification, the mine standard informed by risk assessment outcomes as well as mines operating conditions such as haul road conditions. Injector pipes shall not be re-used unless they have passed a non-destructive test. Where this cannot be guaranteed, new pipes that comply with the OEM specifications shall be used. |
| 2.7. |
A daily inspection of mobile equipment should include the following: |
| 2.7.1. |
A check for oil and fuel leaks; |
| 2.7.2. |
A tyre inspection and pressure test; |
| 2.7.3. |
Checking the integrity of the turbocharger and manifold guards (retrofit kits for older machines to minimize lines and hoses in hot zone where available. |
| 2.7.4. |
An inspection of wiring systems. |
| 2.8. |
Tests of temperature alarms shall be conducted as per mine standard. |
| 2.9. |
Thermostats on electrical motors shall be tested at least monthly. |
| 2.10. |
A 250-hour inspection of mobile equipment shall include the following inspections: |
2.10.1. All sources of heat and all flammable materials.
2.10.2. "V" belts (and adjustment, where required).
2.10.3. Park brake operation.
2.10.4. Battery compartments.
2.10.5. Lubrication lines and fittings.
2.10.6. Fire suppression systems.
| 2.11. |
Brakes should be dynamically tested at least as per OEM and mine standards, with visual inspection for excess wear on a regular basis. |
| 3. |
Mobile equipment maintenance procedures (both rail bound and trackless transport machinery) shall include: |
| 3.1 |
Monthly inspections of extra low voltage wiring to OEM requirements. |
| 3.2. |
Standard procedure for the lubrication of equipment. |
| 3.3. |
A procedure that requires maintenance personnel to remove excess lubricants and flammable materials following maintenance activities. This shall be recorded as part of the maintenance report. |
| 3.4. |
Running-up all equipment to normal operating temperature (20min) inside the maintenance area before being returned back into service. |
| 3.5. |
Maintenance inspections shall identify leaks on equipment, which shall not be operated until these are repaired satisfactorily. |
| 3.6. |
Inspection of hydraulic and fuel hoses for damage and wear at least every 250hrs. These shall be replaced where required. Specific hose check sheets shall be developed for each class of machine as part of this process. Unplanned changes in hose specification and routes shall be avoided. |
| 3.7. |
Ensuring no overloading of tyres and correct tyre inflation pressure. |
| 3.8. |
Where auto-fire suppression systems are specified, fire extinguishing media should comply to one of the following specifications: |
| 3.8.1. |
SANS 7202:2012 Fire protection - fire extinguishing media - powder. |
| 3.8.2. |
SANS 7203-1:2013 Fire extinguishing media - foam concentrate part 1: specification for low expansion foam concentrate for application to water immiscible liquids. |
| 3.8.3. |
SANS 7203-2:2013 Fire extinguishing media - foam concentrate part 2: specification for medium and high expansion foam concentrate for top application to water immiscible liquids. |
| 3.8.4. |
SANS 7203-3:2013 Fire extinguishing media - foam concentrate part 3: specification for low expansion foam concentrates for top application to water immiscible liquids. |
| 3.9. |
Explosives-carrying equipment shall not be allowed into maintenance areas until all explosives and detonators have been removed and washed down. |
| 4. |
The COP shall address the following relating to electrical equipment maintenance: |
| 4.1. |
Electrical equipment maintenance shall be included in a formal maintenance plan or schedule. |
| 4.2. |
Only non-flammable sprays shall be used during electrical maintenance. |
| 4.3. |
Only competent persons shall do electrical maintenance work. |
| 4.4. |
Modifications to an electrical equipment or reticulation systems shall only take place with the approval of an electrical engineer or a statutory appointed person (e.g. electrical supervisor). |
| 4.5. |
New installations should be tested to the requirements of OEM and checked for compliance with fire prevention controls (refer Section 2.3) prior to being commissioned. |
| 4.6. |
Thermal imaging surveys of higher voltage cable joints and appliance shall be conducted every 12 months. |
| 4.7. |
Electrical appliances in ‘significant fire risk’ locations (e.g. workshops, refuelling bays, etc.) shall be inspected on monthly basis. |
| 4.8. |
The maintenance system shall ensure continuing compliance with IP 55 monthly inspection and testing of all electrical equipment associated with explosive storage facilities. |
| 5. |
The following shall be considered to be formal maintenance procedures, including regular inspections: |
| 5.1. |
Fuel storage systems. |
| 5.2. |
Fuel distribution systems. |
| 5.3. |
Fuel nozzles and connections. |
| 5.4. |
Spillage fuel containment systems (e.g. bunds, drains, sumps, etc.). |
| 6. |
The following pre-use checks by equipment operators shall include the following: |
| 6.1. |
Integrity of wiring systems. |
| 6.2. |
Tyre condition and damage (including rocks jammed in treads). |
| 6.3. |
Presence of fuel or oil leaks. |
| 6.4. |
Excessive lubricant levels. |
| 6.5. |
The presence of rags and flammable materials (e.g. paper). |
| 6.6. |
Condition of fire extinguisher and fire suppression system (e.g. charged or uncharged). |
| 6.7. |
For heat sources and flammable materials(e.g. no combustible material in contact with lights). |
| 6.8. |
That the outlets from the operator’s cab are clear and useable. |
| 7.1. |
The results of pre-use checks shall be recorded (e.g. using a checklist) and any defects recorded by the operator. |
| 7.2. |
Any dangerous condition shall be reported immediately to the supervisor and equipment use shall be suspended until condition is rectified. |
| 7.3. |
Completed pre-use check sheets shall be provided to maintenance personnel and any defects recorded in the maintenance system. |
| 7.4. |
All operators shall be trained or instructed in pre-use checks at induction. |
| 8.1. |
A mine shall designate areas where hot work may be performed, such as a welding bay in a workshop. In these areas a general risk assessment should be conducted and all the identified controls applied; |
| 8.2. |
Hot work can be conducted in these areas without a permit only if the appropriate controls are implemented. Any hot work in other areas shall be controlled through the hot work procedure and associated permit; and |
| 8.3. |
A hot work permit system shall be applied for any such activity in any part of a mine outside a designated hot work area. The system shall be based upon a procedure that at least include but not limited to the following requirements: |
| 8.3.1. |
The work or procedure shall be authorized by an appointed person. |
| 8.3.2. |
The provision of adequate flash-back arrestors for Oxy/acetylene equipment. |
| 8.3.3. |
Inspection of the equipment for potential fuel sources prior to work commencing (“pre-work” inspection) must be performed. |
| 8.3.4. |
The removal of any flammable materials in the immediate vicinity of the hot work site before the commencement of any work. |
| 8.3.5. |
The provision and availability of fire extinguishers or other fire-fighting equipment in the immediate vicinity of the hot worksite. |
| 8.3.6. |
An adequate fresh air flow is present at the hot work site. Hot work shall stop in the event of any detectable weakening or stoppage of fresh air flow. |
| 8.3.7. |
Thermal blankets shall be provided to shield any exposed equipment where hot work is conducted particularly where this contains flammable constituents. (focus on making available adequate means of extinguishing fire like water and water hoses). |
| 8.3.8. |
The use of an observer or fire-watch, where required. |
| 8.3.9. |
A thorough inspection of the equipment and work area after work has been completed (“Post-work” inspection). |
| 8.3.10. |
All precautionary measures relating to the transport and storage of gas cylinders should be followed prior to and following the completion of hot work. |
| 8.3.11. |
Use of the appropriate permit form or sheet and follow the standard procedure to record that the above checks have been undertaken. |
| 9. |
The COP shall include reference to the maintenance of cutting and welding equipment. The following shall be considered: |
| 9.1. |
The specifications of the period for the inspection of oxy-acetylene handsets, regulators and hoses. |
| 9.2. |
The specifications of the inspections and tests periods of electrical welding transformers and leads. |
| 9.3. |
In addressing the maintenance procedures for fire suppression systems, the COP shall cover the following: |
| 9.3.1. |
The distribution piping of all automatic fire suppression systems shall be flushed on a routine basis in line with sound maintenance practices. |
| 9.3.2. |
Visual inspections to check fire suppression system lines, nozzle alignment and that debris caps are in place shall be conducted on a routine basis in line with sound maintenance practices. |
| 9.3.3. |
Full discharge tests (pressure test) shall be conducted of mobile equipment or fixed plant automatic fire suppression systems regularly. |
| 9.3.4. |
Full discharge tests shall be conducted of automatic fire suppression systems on remotely operated equipment from the remote operating unit regularly as per mine standard or OEM specification) every three months. |
| 9.4. |
Fire protection systems, including smoke or heat detectors, in high-risk areas (e.g. magazines, refuelling bays, workshops, combustible stores etc.) shall be inspected and tested every six months (alternatively as per mine standard or OEM specification.) |
| 9.5. |
Full discharge tests shall be conducted on automatic fire suppression systems of fuel cells or fuel storage areas every six months and include a check that the operation of the equipment is inhibited following the test. |
| 9.6. |
The maintenance of fire protection equipment shall be undertaken in accordance with relevant SANS. |
National Road Traffic Act, 1996
