Sustainability website / Case Studies 2005 / Xstrata coal / Ravensworth Operations solve industry dragline safety hazard

Ravensworth Operations solve industry dragline safety hazard

The removal of dragline rope socket wedges can now be carried out safely thanks to the ingenuity of a maintenance team from the Ravensworth Operations in New South Wales.

Dragline ropes are changed regularly. Until recently, this process presented a safety hazard, as three workers were required to repeatedly pull a heavy steel boomer back high enough to generate enough force to knock socket wedges out. Maintenance Manager John Green set his team the task of tackling this issue, a common problem for the open cut coal mining industry.

Maintenance team coordinator Paul Scott, boilermaker Mark Parkes, rigger Ron Shuttleworth, fitter David Shearer and dayshift electrician David Pickles considered a range of options, including replacing complete sockets and wedges, using a Kobota excavator with a hydraulic hammer attachment, and using a portable hydraulic press.

The preferred option was to develop a trigger release mechanism for the boomer that enabled one operator to control the release from the safety of an area adjacent to the mobile crane cab. As a result, all personnel are removed from the area of risk.

"Many complicated methods had been considered and trialled but this simple solution has proven to be the most successful by far," Paul Scott said.

David Pickles said his experience as a glider pilot and pilot trainer gave him the idea to utilise the glider tow release mechanism to safely release the boomer.

"I was thrilled to see it operate and prove to be so successful. It was also great to be able to contribute to the improvement of the safety of my workmates," he said.

Modifying the existing boomer has a number of advantages including preventing metal from splintering on impact, enabling the boomer to be adjusted to variable angles and force, and allowing the tightest wedges to be removed at a single stroke.

This initiative won the People's Choice Award in recognition of its importance for open cut mining at the 2005 New South Wales Minerals Council's Safety Innovation Awards. John Green said the boomer could be easily applied across other open cut operations to prevent injuries.

"This is a simple, cost-effective solution that came about by positive input from personnel in the field. They knew there were hazards involved in this process and were determined to find a solution," he said.

Mark Parkes said the boomer had operational as well as safety benefits, allowing the maintenance team to complete the job more quickly.

"We can now crop the ropes in no more than two-thirds of the time it used to take us. The previous risks have been eliminated," he said.