safety regulations m 324 01 i

8/14/2019 Safety Regulations M 324 01 i

1/18

INSTRUCTION

MANUAL

S A F E T Y R E G UL A T I O N S

F O R I N S T A L L A T I O N S O F

C R US H I N G A N D S C R E E N I N G

M-324

Rev. 01 March/03


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SAFETY REGULATIONS

FOR INSTALLATIONS OF

CRUSHING AND SCREENING

M-324

Mar/03 1(1)

CONTENTS

Introduction 1

Extra Safety Precautions 2

General Safety Precautions

Personnel Safety 3

Work Area Safety 3

Crushing Equipment Safety

Crushers (SEE SPECIFIC MANUAL OF MACHINE)Impactors (vertical shaft Barmac type) 4Screen

5Feeders 7

General Safety Precautions for Installations of Screening

and Crushing7

Electrical Safety 10

Flammable and Hazardous Materials Safety 11

Pressurized Systems Safety (Air and Hydraulic)12

Welding Safety 13

Ten Safety Rules 14


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WARNINGThis manual must be studied in detail before the installation work starts. If you disregard theinstructions given in this manual there is a risk of serious injury to personnel and/or damage toyour equipment.

INTRODUCTION

Metso Minerals manufacture equipment intended for the feeding, crushing, grinding,scrubbing, sizing and sorting of minerals and similar solid materials. Examples of products arefeeders and screens of various types and sizes, double toggle and single toggle jaw crushers,cone crushers with or without computerized control systems, vertical or horizontal shaft

impactors and scrubber barrels. During the design and manufacture of the equipment, a lot ofeffort is put into the avoidance of health and safety risks.

A single machine, delivered from Metso Minerals, will always be used as a component in amineral processing plant. It is therefore virtually impossible for us as suppliers to provideoperator instructions for every conceivable control system configuration in which the machinecould operate.

This manual gives information on safe installation, operation and maintenance. It is notintended as a detailed manual for a specific machine. Its purpose is instead to alertcustomers, operators and maintenance personnel to the general hazards and risks which canbe encountered in a crushing plant.

Our maintenance instruction manuals for individual machines give more detailed informationregarding your equipment. Despite this, additional training by Metso Minerals may benecessary. Never hesitate to contact our service organization.

Historically, most injuries in crushing and screening plants occur during maintenance, althoughsome occur during the inspection of moving parts or while clearing material blockages. So,this safety manual emphasize safety precautions when these activities are undertaken.

To avoid potential safety risks it is important that:

The recommendations in instruction manuals are studied and followed.

Personnel are regularly given training on maintenance and safety.

General and official safety regulations are followed.

Dangerous areas are marked with warning signs.

The appropriate equipment and tools are available.

The owner and management live up to their responsibility to make sure that effectivesafety programmes and regulations are worked out and are followed by all personnel.


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SAFETY REGULATIONS



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EXTRA SAFETY PRECAUTIONS

Our instruction manuals and other documentation contain important information which must be

read and understood by all users before they operate the equipment. To make it easier tonotice information in our instruction manuals directly concerning USER SAFETY, we areintroducing in the text the following terms and symbols:

WARNING

Important information which alerts you to a situation which could lead to serious injury or deathif you not follow the instructions given.

CAUTION

Important information which describes how you avoid damage to a machine and its systems orhow you avoid a situation which could cause personal injury.

NOTEAdvice about operation, inspection and maintenance of a machine and its systems.

GENERAL SAFETY PRECAUTIONS

WARNINGThe following list should be considered as a guide only. There may be other conditions andvariations in the operation of this equipment that are not covered in guide.

The purpose of these, is to make all personnel aware of the general hazards and dangerous

situations that exist around the equipment and the work area.


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SAFETY REGULATIONS



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PERSONNEL SAFETY

1. Read and understand each one of the warnings, cautions and instructions in the

instruction manual and on all signs and information plates on and around the equipment.

2. Report all accidents immediately to your supervisor. Consult a doctor or medical

personnel as soon as possible if personal injury is involved.

3. Keep a list of emergency telephone numbers close to the telephone and inform all work

area personnel about the location of the list.

4. Do not operate or work around equipment while under the influence of alcohol,

medicines, tranquilizers or other drugs that can make you less alert or affect your

judgment.

5. Take precautions to keep hair and loose fitting clothing from being caught on moving

parts or controls.

6. Wear safety glasses whenever there is any danger of flying debris, stone fragments,

objects or dust that could enter the eyes, and when required by operating regulations.

Be extra safe - always wear eye protection. Take good care of your eyes.

7. Wear gloves whenever possible to protect hands and fingers from cuts, scrapes, burns

and solvents.

8. Always wear a helmet and safety shoes when appropriate for the work being done and

always when required by local or national regulations. Around and beneath material

transfer points - between conveyors or feeders and crushers, for example - there can be

a risk of falling material. Make sure that suitable guards and warning signs are provided.

9. Remove rings, watches, necklaces and bracelets before working in the plant.

10. In areas where noise levels are high, wear hearing protection devices.

11. Wear a breathing apparatus or mask whenever appropriate i.e. when painting or working

with chemicals, solvents and other substances that may be hazardous to your health.Remember that there is a risk of silicosis when there is silicious dust in the air.

12. Do not take chances with your back. Use lifting and moving devices to help you with your

work. Always lift with your legs, not with your back.

WORK AREA SAFETY

1. Keep the general work area clean and free of debris. Avoid stone or other material build-

ups on walkways, platforms, ladders and passage places in general.


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2. Do not allow unauthorized personnel in or around the work area. Keep a check on who

is in your work area all the time. If necessary, keep a list.

3. Keep equipment surfaces that will be touched by hands and feet clean, dry and free of

oil or grease.

4. Keep hand rails, guard rails, ladders and platforms clean, dry and free of oil or grease.

Store parts and tools in the designated places when not in use.

5. Keep safety equipment in a designated place and ensure that work area personnel know

the location and the proper use of the safety equipment.

6. Make a daily check of starting alarms and warning devices in the work area, and ensure

that each device is working properly before starting or operating the equipment.

7. Do not stand under or allow anyone else to stand under equipment that is being hoisted

or suspended. Use a safety hook or hook with a safety latch when hoisting equipment

and use spreader bars when necessary.

8. Learn the weight limitations and clearances in and around your work area and for the

equipment in use.

9. Do not overload walkways. They are intended for personnel, not equipment.

10. Be alert to conditions that may obscure vision in and around your work area.

11. Always isolate the drive motor(s) of equipment before removing guards or carrying outany inspection or maintenance work.

IMPACTORS (VERTICAL SHAFT BARMAC TYPE)

1. A metal detector must be installed before impactor to avoid the entrance of strangebodies with the feeded material.

CAUTION

Metalic bodies in the feed could cause serious damages to the crusher.

2.The impactors are usually driven by V-belts.

CAUTION

A fixed guard always should be installed to protect the V-belts. Should have possibility ofcheck the belts tension.

The guards should be designed of form to perform the safety applicable regulations.


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SAFETY REGULATIONS



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Mar/03 5(14)3. Start the machine

CAUTION

Verify that all the inspection covers and access doors has been closed and locked, andverify too that all the drive guards has been assembly before start the machine.

4. The protection key against vibration was developed to protect the machine against theeffects of hard vibrations. If by any reason, the vibration be too hard, a relay will beactive. This may be used to turn off the machine, or to sound a alarm.

CAUTION

All the machines should have a protection system suitably assembled.

SCREENS

1. During the screening the main dangers are ejected stones, dust or noise.

The following equipments may be supplied by Metso Minerals to reduce these risks.

The screen may be partial or total cloister. This not only will eliminate the dustemissions, but will supply also protection for the operators against ejected stones. Inthe same form will reduce the noise emanated from screening surface andtransmitted by the air.

The noise switch may also be reduced using not metallic screening surfaces, asrubber or polyurethane. In this mode the changes of the screening surfaces will beless frequent, reducing the risk of injuries.

The feed box and the discharge lips with rubber liners also is resistant to impacts and

reduce the noise switch.

The steel coil springs may be replaced by rubber isolators, again reducing the noiselevel and structural vibration, particularly during the start e stop. The risks presentedby bite points between the spirals of spring will be eliminated.


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CAUTION

Be extremely careful when work near to the steel coil springs.

2. Gaps on installation

CAUTION

Should exist an adequate gap between the screen body and structures and adjacentcomponents for avoid risks of bits and for allow the free movimentation of the screenbody.

3. Make sure always that all the safety guards has been assembled before operating theequipment.

4. If possible, avoid welding works in the body of the screen, accepted that this works mayincrease the tensions in the screen body and possibly cause damages.

5. In the cases that the screen has been ordered without walkways, adequate walkwaysshould be manufacturing around the screen, equipated with guardrails and footers.

CAUTION

Be extremely careful when work around vibration screens in operation. Always use safetyhelmet and protection glasses for avoid injuries.


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SAFETY REGULATIONS



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FEEDERS

CAUTION1. Be extremely careful when remove obstructions of material manually with levers etc.

Provide a free space around the equipment to be secure that the operator dont havereason to approximate of the feeder when this has been working.

2. When the material is being discharging for inside of a feeder hopper that precede afeeder, there is a serious risk of material that could fly. The inspection covers of theequipment closure should be strongly fixed.

3. Be extremely careful when work next to the steel coil springs because there is a riskdue the bits points between the spring spires.

4. Be equally careful when work next to the feeder, because may exist several pointswhere the operator may pince body parts between the feeder and the steel structurearound this. This is important, specially in the moments of start or stop the feeder.

5. If possible, avoid welding works on the feeder body, once that this may increasing thetensions on the feeder body, and possibly could damage it.

GENERAL SAFETY PRECAUTIONS FOR CRUSHING INSTALLATIONS

1. In a crushing plant the environment could be dusted, noise, and exposed to badconditions of weather.

NOTE

A cabin should be provided for give protection to the operators.

NOTE

Should always exist a possibility of observe the material that is being feed for the primarysection of a crushing plant, or direct from a platform or cabin next to the crusher or byan remote observation place inside of a control hall.

2. In cases that the feeders or crushers are preceded by a dropped hopper, there is alwaysthe risk that vehicles give reverse speed for inside hopper.


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NOTE

Always install transversals stop rabbets on the total width of the access way.

The total height of these rabbet should be on minimum 50% less of the rear wheelsdiameter of the biggest used vehicle.

Additional safety devices, as guard-rails should be installed around the rest of the hopper.

3. Lifting devices of adequate capacity should be available for allow the appropriatedservice performing for all the machines.

4. Crushing plants sometimes may cause dust conditions.

CAUTION

If the dust concentration on atmosphere exceed permitted levels, should be provided theextraction or the dust suppression.

The Metso Minerals may supply the adequate equipment.

The more usual equipment for dust extraction is the dust collector.

5. Do not modify, erase or remove alert and information plates.

6. Before install mobile equipment, be sure that the floor is firm and leveled. Be sure that allthe support and locking devices be security in its places. When applicable, follow therecommendable procedures by the supplier for support and lock the equipments.

7. Before move mobile equipments verify that the breaks and the traffic lights has beenworking correctly. Be sure that the support leg has been left enough for make sure thenecessary gap for a secure transport. Verify that do not exists free objects that may fallout during the transport.

WARNING

Never go up on the equipment in transport, or that is being left, or permit that anotherperson do that.

8. Examine all the components of the equipments before each operation turn for make surethat dont exists damaged parts or with damage suspects.


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NOTE

Repair or replace damaged parts before start or operate the equipment. Use only

original parts.

9. Start or operate the equipment

CAUTION

Before start or operate equipments, look around the work area and around theequipment for check that dont exist people, animals, tools, pieces or another strangeobjects inside, above, below or around the equipment. Be sure that all the guards hasbeen appropriately installed and in good conditions of work.

10.Before start the equipment, be sure that all the people of the work area and possiblevisitors knows that the equipment go start.

NOTE

Use appropriate device, as sirens or blinker lights, for alert people and visitors.

11. When start the equipment, follow the sequence recommended by the supplier. Dontpermit that no-qualified peoples start or operate any equipment without the adequatesupervision of a professional operator.

CAUTION

Never let the equipments control without operator. Always have a qualifiedoperator assubstitute if you need go out.

12.During the start and the operation of the equipment, be alert respect of inappropriatereadings, visible defects, smells or sounds, that could be an alert about a potential risk.

Turn off the equipment immediately, following the established stop, if any insecurecondition occurs.


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SAFETY REGULATIONS



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Mar/03 10(14)13. Act with extreme careful when exist exigency that any equipment should be operating

during an inspection, maintenance, lubrication or adjust.

WARNINGThis only could be allowed if go absolutely essential and may be executed under thesupervision of a qualified supervise. In normal circumstances the machine should bestopped and the safety keys locked before the execution of any work.

14. Accomplish all the inspection services, maintenance, lubrication and adjust with careful,and in follow with the recommended procedures by the manufacturer.

15. Always install adequate points of light and force for make easy the maintenance.

16. Be extremely careful when move assembly units over tracks. The operator that work withthe radio control should have absolute certainty that dont have people working or goingup the equipment during the movementation.

WARNING

Stay far from the unit when the tracks were working.

CAUTION

Be sure that the floor where the assembly unit on tracks is going to be movemented beadequate, if not the unit could sideslip or fall down.

ELECTRICAL SAFETY

1. Permit only trained and competent personnel to work on electrical components, in theplant or on any equipment.

2. Always assume that an electrical circuit is live until it is proven dead by proper testingprocedures.

3. Lock out and signalize the electrical controls before performing any inspection,maintenance, lubrication or adjustment procedure on a machine.

4. Repair or replace electrical wires, cables and connectors that are broken or damaged inany way.

5. Check that electrical earth wires, motor and power cable connections are properly andsecurely connected before starting any equipment.

6. Make sure you know the location of all power lines and underground cables. Use extremecaution when working around these areas. Memorize the location of all main electrical

isolating switches.


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9. Do not use flammable or combustible substances such as gasoline, kerosene or dieselfuel for cleaning parts. Always use a nonflammable solvent for cleaning.

10. When using epoxy-resin based materials, follow the manufacturer's recommendedprocedures and precautions.

WARNING

Mix and pour epoxy materials in an open or well ventilated area. Do not burn cured resinwithout adequate ventilation. Avoid skin contact with uncured epoxy-resin materials.

11.Always inspect and charge batteries in an open or well ventilated area. Do not permitsmoking or open flames near batteries.

WARNING

Remember that batteries can contain explosive gas.

12. Properly dispose of waste, drained fluids and hazardous materials with due regard to andin full accordance with all national and local environmental, safety, transportation, andother regulations and ordinances. Make sure that all personnel are familiar with theseregulations.

13. Wear the appropriate clothing and protection devices, and follow the recommendedprocedures when working with hazardous, flammable and combustible materials.

PRESSURIZED SYSTEMS (AIR AND HYDRAULIC)

1. Do not perform maintenance on pressurized system components without first relievingALLpressure in the system.

2. Do not make internal checks on pressurized oil or fluid system reservoirs or levels until

ALLpressure in the system has been relieved. Pressurized oil and air are dangerous ifreleased incorrectly. Oil and air under pressure can get very hot; use extreme cautionand allow the system to cool before working on it.

3. Do not attempt to disconnect an air line or hydraulic line from a cylinder or othercomponent unless ALL pressure in the system has been relieved.

4. Do not attempt to remove an air or hydraulic cylinder clevis from its attachment unlessALLpressure in the system has been relieved.

5. Do not operate pressurized systems with worn or damaged hoses, valves or fittings.Replace defective components before pressurizing the system.


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6. Do not attempt to disassemble air or hydraulic cylinders unless you have been trainedand authorized for such maintenance.

WARNING

7. Never adjust pressure relief valves beyond the recommended values.

8. Follow the manufacturer's recommended inspection and maintenance procedures forpressurized systems to ensure that safe operating conditions exist at all times.

WARNING

9. Take extreme care when working with hydraulic accumulators. They must never be

heated or subjected to welding or mechanical damage.

WELDING SAFETY

1. Any welding or cutting operations should only be performed by experienced welders whoare familiar with the welding equipment and the materials to be welded.

2. Take all necessary precautions to avoid dropping sparks or welding splatter on belts, hoses,tanks or other parts of equipment, or on personnel in the work area. Always keep the risk of fire

in mind.

WARNING

3. Attach the welding earth cable as close as possible to the piece being welded to avoiddamage to the equipment and potential injury to personnel.

4. Always consult with the manufacturers of the equipment to be welded before any weldingoperation.

5. Never weld vessels or pipe work which are pressurized.


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TEN SAFETY RULES

1. Support all efforts to make your work-area safe and healthy.

2. Act responsibly and with concern for the safety of others, as well as yourself.

3. Check all tools and protective equipment frequently, to make sure they are in safeworking order.

4. Educate yourself and others in the hazards associated with your job so that they can beavoided in a safe manner.

5. To avoid injury and damage, familiarize yourself in advance with the risks and safetyaspects of procedures which are new to you.

6. Think over accident and injury possibilities before starting on any project. Takeappropriate precautions to protect yourself and others.

7. Warn others of the possibility of accidents and injuries if you see them working unsafelyor creating potential hazards.

8. Be alert for changes in working conditions and process characteristics.

9. Report unsafe acts and conditions immediately to your supervisor. Don't assume thatsomeone else will do it.

10. Keep your work area and your tools clean. Pick up tools and materials after use andreturn them to the appropriate storage place.


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NOISE LEVELS IN INSTALLATIONS

OF CRUSHING AND SCREENING

ATTACH I

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March/03 1

(2)

Measurement Conditions

All the values are equivalents continuous sound levels (Leq) measured with a integrative measurerof sound levels, during an interval of 60 seconds. All the values are measured with a approximatedistant of 1m from machine, to 1,6m height of the floor level or from the platform whenapplicable.

The sound levels are approximate values. The sound levels depend of a factor number, as forexample screens, if the cloister against dust is assembly or not, installation arrangements andfeed of the equipment, dimension and work index of the feed material, size of the drive motor,etc Different kinds of screens cause influence on the screen sound levels.

Cone Crushers, Jaw Crushers and Hammer Mills

Product seriesTest performance inthe service station(without material)

dB (A)

Typical Values inperformance with

materialdB (A)

Cone Crushers 95 95-106

One toggle jaw crusher 87 102-108

Double toggle jaw crusher 87 102-108

Impact crushers 85 100-110

Vertical Shaft Impactor - Barmac 90 93-105

Hammer Mills 83 95-105

CAUTIONAll the people should use ear protector


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NOISE LEVELS IN INSTALLATIONS

OF CRUSHING AND SCREENING

ATTACH I

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(2)

Screens and Feeders

Product seriesTest performance inthe service station(without material)

dB (A)

Typical Values inperformance with

materialdB (A)

Screens type SH 85 90-100

Screens type LH 85 90-100

Vibrating Grizzly 85 90-100

Screens type XH 85 90-100

Vibrating Trough 85 90-100

Feeders type MV, MVS e AV 90 95-105

Vibraline Top Feeder 85 90-110

CAUTION

All the people should use ear protector

safety regulations m 324 01 i

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