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1Department of Consumerand Employment Protection Resources Safety

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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:[email protected]

or visitwww.docep.wa.gov.au/ResourcesSafety

Toolbox presentation: Classified plant requirements for mining operations and registering classified plant October 2007


Introduction

Are you confused and unfamiliar with classified plant?

If you are then you’re not alone!

This presentation provides information on:

Resources Safety’s requirements for registration of classified plant

frequently asked questions relating to classified plant

tips and “rules of thumb” when dealing with classified plant


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


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


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


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


From left: Jim Farnworth (Karratha), Barry Evans (Kalgoorlie), Rod McFarlane (Perth), Brett Boneham (Perth), Scott Kay (Perth), Dino Busuladzic (Perth)

The team


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


Registration process cont.

Elements that must be dealt with when making and reviewing applications:

1. Authorisation of applicant

2. Assessment of plant

3. Application preparation

4. Application submission

5. Review of application

6. Issue of registration number


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 doesn’t have or hasn’t included a copy of their authorisation letter from the Registered Manager or Principal Employer


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


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


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


What about hire and contractor’s 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


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


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


5. Review of application

Please remember that inspectors don’t 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


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


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


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


Pressure equipment


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


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


What pressure vessels are registrable?

Pressure vessels categorised as hazard level “A”, “B” or “C” according to AS 4343

Boilers


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 you’re 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


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


Pressure equipment in summary and important tips


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 >150L 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


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


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 manufacturer’s 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


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


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


Cranes


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


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?


Hoists


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


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?


Workboxes suspended from cranes


What about man baskets attached to crane booms?

Not deemed to be workboxes suspended from cranes

Not required to be registered with Resources Safety


Further information

Go to Resources Safety website and look for “classified plant” www.docep.wa.gov.au/ResourcesSafety

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 [email protected]

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Documents

classified plant requirements

classified plantoctober

classified planttips

registration proceedsif

issue registration numbers

mining operations

resources safetys requirements

team of inspectors