Coal Inspectorate | Alert | No.454 V 1 | 14 November 2024
Crowd cylinder failures on load haul dump machines
Summary
- RSHQ has reviewed data of high potential incidents (HPIs) at Queensland coal mines and found 26 crowd cylinder failures on load haul dump machines over a 14-year period.
- No one was injured but these incidents have the potential to seriously harm coal mine workers.
- Learnings and recommendations are available below.
Issue Explained
A review of coal mine HPIs reported to RSHQ over the period 2009 to December 2023 has identified 26 crowd cylinder failures, on load haul dump vehicles (LHDs). No one was injured in these incidents but there is a serious risk that LHD crowd cylinders may fail when coal mine workers are working in or near man baskets, bolting platforms or implements attached to the LHD lift arms.
The LHD is a multipurpose machine by design, as such it can be one day mucking out stowage, the next transporting heavy loads, the next lifting men above ground level. Due to the lift arm geometry of most underground coal mine LHDs, a failed crowd cylinder can cause the implement to drop and rotate about the lower load arm pivot joint. Coal mine workers (CMWs) working in a man basket, on a bolting platform or similar attachment, or in proximity on the ground, may be placed at immediate risk of serious injury.
Based on investigation reports received by RSHQ there appears to be multiple crowd cylinders failure modes. Fixed time replacement of crowd cylinder may not be effective in eliminating failures.
Learnings
- Make sure hazards associated with CMWs working on or near LHD implements have been identified.
- Implement effective and sustainable controls reducing the risks identified to an acceptable level.
- Additional examples of changes that SSEs can make include, but are not limited to:
- Review inspections and maintenance schemes for the machines
- Restrictions on who can use the machines
- Secondary measures restricting movement of the basket should a cylinder fail
- Contact the original equipment manufacturer (OEM) for LHDs and seek engineering controls to prevent implements from dropping and rotating about the lower load arm pivot joint in the event of a failed crowd cylinder.
Investigations are ongoing and further information may be published as it becomes available. The information in this publication is what is known at the time of writing.
We issue Safety Notices to draw attention to the occurrence of a serious incident, raise awareness of risks, and prompt assessment of your existing controls.
References and further information
CMSHA s42
Contact: Qldminesinspectorate@rshq.qld.gov.au
Issued by Resources Safety & Health Queensland
Security: This information is a guide only and is issued to promote security through experience. It is not to be taken as a statement of law and must not be construed to waive or modify any legal obligation.
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