Code of Good Practice

Management of Emulsion Pump Trucks

Publication No. 31November 2001

CONTENTS

1. Preface

1.1 Transporting ingredients/ mixing and pumping on site

1.2 Transporting non-sensitised emulsion matrix/ mixing pumping sensitising on site

1.3 Transporting sensitised emulsion

2. Consideration of Hazards arising from the Bulk Explosives Truck Activities

2.1 Vehicle and process equipment

2.2 Personnel

2.3Raw materials

2.4 Precautions against Truck Fires

3. Loading the vehicles

3.1 Loading the tanks with dry components

3.2 Loading the vehicles with liquid components

3.3 Environmental Considerations

4. Calibration of the vehicle and quality control

5. Maintenance and Safety Systems

6. Production at Customers Premises

1.PREFACE

This Code deals with the management of emulsion pump trucks, and concerns itself with the safe operation of equipment, calibration and production as well as with the management of risk.

This Code does not deal with the transport or storage of raw materials or matrix, nor does it deal with the design of vehicles. These items are dealt with in the CGP "Standards for the Transport, Storage, Mixing and Handling of Bulk Emulsion Explosives and their Components" (Publication No. 26).

Bulk emulsionexplosive compositions can be transported in three different ways:

1.1Transporting ingredients/ mixing and pumping on site

One method for manufacturing bulk emulsion explosives is to transport the non-explosive materials to the location of use, where a sensitised emulsion product is produced, and subsequently pumped down a borehole.

While transporting non-explosive products to site, explosive regulations are not involved.

1.2Transporting non-sensitised emulsion matrix/ mixing, pumping and sensitising on site

A nonexplosive emulsion matrix is manufactured in a fixed location factory, and transferred to a bulk truck. The final manufacturing process is completed by sensitising the emulsion matrix, in such a way that the explosive is only produced either on the truck or during or after loading the borehole.

Clearly, under this process, the transport condition of the nonexplosive, nonsensitised emulsion matrix is not covered by explosives regulations. This assumes that the non-sensitised matrix product is classified as 5.1 in the UN “Orange Book” or alternatively is not classified at all as “Dangerous Goods”

1.3Transporting sensitised emulsion

An alternative method of production of bulk emulsion explosive is to manufacture and sensitise the emulsion within a fixed location factory. Under these conditions the sensitised emulsion is transported from the fixed location factory to the point of use and then pumped into the borehole. During the transport process the explosive falls into the Class I category.

The recommendations contained in this Code have been drawn up after indepth consultation with experts within the industry and those skilled in the manufacture of emulsion explosives and, therefore, represents the best possible advice in current terms. However, National Regulations may, from time to time, be introduced which differ in some respects from these recommendations.

It is emphasised that where such differences exist, the national and local legislation should always take precedence over this code.

2. CONSIDERATION OF HAZARDS ARISING FROM BULK EMULSION TRUCK ACTIVITIES

These hazards, which may arise from the operation of bulk trucks, can be considered under three main headings:

a)Vehicle and Process equipment

b)Personnel

c)Raw materials

2.1Vehicle and Process equipment

The vehicle and equipment that form an emulsion pump truck are complex. They possess the potential for being extremely hazardous. A risk assessment of bulk emulsion trucks should commence at the design stage with a Hazard and Operability Study or equivalent.

Issues to be considered during the Study may include

i)The protection devices, including:

  • Maximum safe operating pressure, temperature and flow rates
  • Knowledge of raw material, intermediary and explosive characteristics
  • Appropriate means of monitoring
  • Integrity of protection equipment
  • Likelihood and consequence of protection equipment failure
  • Safety shut-down systems
  • Pump design

ii)Material compatibility, including:

  • Likelihood of corrosion due to raw material presence
  • Individual material characteristics
  • Potential for fatigue/stress/corrosion effects with incompatible materials
  • Consequence of material failure

iii)Parameters for the safe operation defined, including:

  • Normal acceptable parameters for pressure, temperature and flow rates
  • Inprocess testing/monitoring acceptable limits
  • Final testing/monitoring acceptable limits
  • Actions defined when parameters are exceeded

iv)Clearly defined procedures, including:

  • Formal quality procedures drafted, reviewed, issued, controlled and authorised
  • Testing and commissioning procedures
  • Training and communicating work instructions
  • Emergency procedures drafted, tested, issued and communicated

v)Critical safety tests, including:

  • Critical safety parameters identified and categorised
  • Schedule of safety tests compiled
  • Associated procedures and records established

General risks identified as being significant are addressed by formulating an action plan.

2.2Personnel

The Personnel element of operating a bulk emulsion truck is probably the most important as in many cases human actions either exacerbate or terminate a chain of unforeseen events which can lead to an accident. Individuals collectively form a team or a crew. Each, however, has his own perceptions, motivations and experiences that lead them to certain decisions or actions. Experience and cultural values play a very significant part in people's actions. To ensure that the selected individual is the most suitable person, a procedure for selection like the following is recommended:

The process of selection should be the same for internal employees as for external applicants

Recruitment / Selection

a)Job Description for a Bulk Truck operator drafted and agreed.

b)Drafted and agreed Personnel Specification for the position.

This may take into consideration:

  • Experience
  • Physical makeup
  • Attainments
  • Special aptitudes
  • Interests
  • Disposition
  • Motivation
  • Circumstances
  • Short-listing criteria agreed

c)Applications invited and short-listed in accordance with criteria

The process of selection may include some or all of the following:

  • Knowledge of organisation
  • Problem solving
  • Motivation
  • Teamwork
  • Attendance
  • Communication skills
  • Attitude to customers
  • Initiative
  • Personal Profile Analysis
  • Work instruction compliance
  • Fork Lift truck licence
  • Shot-firing knowledge
  • ADR licence

Training

Using the Job Description previously drafted for the selection process, a Training Needs Analysis should be formulated for bulk emulsion truck Operators. This Analysis illustrates the skills/knowledge and experience that may be required before they undertake actual training with the truck.

The following items should be considered:

a)Appropriate Driving licence

b)Fork Lift Operators licence

c)Pump truck systems awareness

d)Maintenance / defect repair

e)Safe systems of work (Permit to work)

f)A.D.R. certificate

g)Approved Shotfiring course

h)Knowledge of Mines and Quarries Regulations

i) Knowledge of raw materials involved

j) Understanding of the manufacturing process

The training manual may include the design of the process, protection devices, operating procedures, critical safety tests and safety data on the raw materials. Training should then be arranged to communicate the contents of the training manual followed by an assessment to ensure that sufficient understanding has been retained

Regular retraining should be considered

2.3 Raw Materials

Instructions and Safety Data Sheets of all substances should be carried on the vehicle and the information concerning safety should also be provided to the customer.

2.4Precautions against Truck Fires

2.4.1General

Truck fires when transporting or loading sensitised explosives or non-sensitive explosive raw materials can lead to extremely dangerous situations and, while there have been many fires on trucks carrying non-sensitised emulsion explosives ingredients that have not lead to detonations, fire must still be regarded as a major potential hazard.

Truck fires involving finished explosives (e.g. sensitised bulk emulsions) obviously present a greater hazard than truck fires involving only raw ingredients.

Nevertheless, the prevention of truck fires is seen as a major safety objective in the “Management of Emulsion Pump Trucks”.

The combination of a standard truck chassis and a complicated loading, mixing and charging unit places very high demands on the design and maintenance of vehicles.

In addition, these factors also demand the highest possible standards of discipline and control in the operation of the vehicles. Drivers and operators are expected to have a keen sense of awareness of the danger of truck fires and the following indicates some of the common causes of fires, with which the driver/operator should be familiar.

2.4.2Common Causes of Truck Fires

  • Life in the cabin ( cooking, coffee brewing, smoking, etc.)
  • Electrical short – circuits.
  • Electric power overloads.
  • Radiation from hot surfaces (e.g. exhaust systems).
  • Leakage of flammable liquids.(diesel, oils, hydraulic oils etc.)
  • Presence of easily ignited combustible solids. (paper, wood chips, sawdust, etc.)
  • Overheated tyres. (improperly inflated; improperly installed)
  • Malfunctioning brakes.
  • Spontaneous fire in cargo.
  • Auxiliary diesel heaters.
  • Cooling systems for cargo.
  • Traffic accidents

Almost all of the above items are in the category of ”it should never happen”. Nevertheless, major truck manufacturers have identified these as the main reasons for truck fires.

2.4.3

Clearly, immaculate cleanliness, high standards of preventative maintenance,and careful drivers/operator training should help to minimise the risk of truck fires from the causes identified above. However, the following non-exhaustive list of measures to assist in the prevention of truck fire hazards may be useful:

  • Risk analysis at the design stage of the truck and auxiliary equipment to ensure the highest possible standard of machinery.
  • High standards of preventative maintenance.
  • High standards of cleanliness, both on the vehicle and in the engine, especially when the vehicle is being used in rough and dirty conditions as in some open pit mining operations.
  • Pressure guards and temperature gauges for brakes and tyres.
  • Daily safety checks.
  • Maximum speed governors.
  • No smoking; no cooking; no heating of soup/coffee etc.
  • Automatic fire alarm systems.
  • Automatic fire fighting systems

3. LOADING THE VEHICLES.

If people are working on the top of the truck suitable arrangements must be made to prevent falling accidents.

Whenever sensitive and or hazardous raw materials, (such as aluminium or ammonium nitrate) are being loaded this should only be done under appropriate conditions.

3.1 Loading with dry components

Care should be taken on loading so as not to overload containers, and the entire truck.

3.2 Loading with pumpablecomponents

Operators present during the loading operation must wear appropriate personal protective equipment. During loading with hot concentrated saline solution (SiteMixed-System) only that which is required is loaded so that unused solution cannot crystallise in un-insulated tanks.

During pumping no unauthorised persons should be present. For loading liquid trace components, cut-off systems should operate to stop further loading when the maximum level is attained.

After loading the vehicle, the operator should verify that all systems (pumps, mixer, steering systems, etc.) are functioning properly and that all seals and valves are closed. Following loading the transfer pump should be cleaned.

3.3Environmental Considerations

The employer has a duty to ensure that personnel understand the environmental hazards associated with each chemical carried on the pump truck. A suitable training program should be conducted for these personnel in environmental awareness and also in procedures to be carried out in the event of a spillage or incident that might result in environmental damage.

The main environmental risk associated with pump trucks is the spillage of material which is rich in Nitrates. Nitrates constitute a risk to marine life and so spillages must be cleaned up immediately.

Spillage of materials should be treated as directed by the relevant material safety data sheet. Spilled matrix should then be disposed of in the proper manner.

During the charging operation there is a risk of spillage of emulsion around the mouth of the borehole. It is important that the charging personnel exercise care to ensure that this spillage is kept to a minimum.

4.CALIBRATION OF THE VEHICLE AND QUALITY CONTROL

To ensure the quality of pumped explosives and the accuracy of their composition, care must be taken to verify that the quantities of raw materials used in a given time are consistent and accurate. There are various differing methods of ensuring this and these invariably entail the accurate calibration of delivery equipment such as augers.

Routine calibration should be undertaken at regular intervals. Additional quality control steps can be taken by taking samples and making regular and appropriate testing.

Sometimes it is possible (depending on local regulations) to transport samples back to the laboratory to verify composition.

5. MAINTENANCE AND SAFETY SYSTEMS

Regular routine maintenance of the vehicle and of the mixing and pumping apparatus on the vehicle are essential.

Maintenance work should be strictly controlled in accordance with the company’s maintenance management system

Routine checking and maintenance schedules should be established for all moving parts of the equipment used for loading, mixing, and pumping of emulsion ingredients.

As far as the vehicle maintenance is concerned, it should be noted that, since a very large part of its use will be "off road" in frequently very rough conditions, the maintenance plan should take these factors into consideration.

The truck operator is in a special position to indicate any mechanical deficiencies of the truck either in terms of straightforward vehicle operation or in terms of loading, mixing, and pumping. Therefore, it is considered advisable that the truck operator should have a daily checklist to confirm that the vehicle is in good overall working order and a reporting system whereby any defects are brought to the attention of the appropriate maintenance people.

The truck should only be used in weather conditions for which it is designed. For example it may be advisable to cease operations at extremely low temperatures.

Safety Systems must be tested periodically, the results recorded and appropriate actions taken if necessary

6.PRODUCTION AT CUSTOMER PREMISES

The manufacturing of explosives on site relocates the interface of production from the factory to the place of use. The operators may have to be fully trained and be capable of the work of both a blaster and an explosives production operator, depending on the contract.

Having evaluated and addressed all of the hazards that are foreseen arising from operating the truck, attention should be given to the hazards arising from the activities and the environment within the customers' premises. The risks across a range of locations have to be assessed by a suitable approach. A checklist type form would be helpful. Within this checklist one should ensure that national legislative requirements are being complied with. This will provide documentary evidence that safety is a significant element within service.

A proposal for a checklist is described below. The activities may be split into four items:

  1. Prior to arrival
  2. Arrival on site
  3. Route to blast site
  4. At blast site

For each item one has to regard several hazards and concerns. These might include:

1.Prior to arrival

-understand contract between supplier/user.

-face profile available

-calibration of profile equipment

-drillers log available

-knowledge of shotfirers rules

-knowledge of emergency procedures

-suitably trained operators

-suitably qualified shotfirers

-mechanical state of bulk truck

-maintenance state of truck process

-truck calibrations

-safety checks

-knowledge of specific site rules

2. Arrival on site

-contact with responsible person

- site hazards (e.g. dust, noise traffic)

-appropriate protective clothing worn

-rules for site arrival

3.Route to blast site

-accessibility

-volume of vehicular traffic

-visibility of other traffic

-mechanical state of quarry vehicles

-edge protection

4.At blast site

-material falling from height

-stability of ground for truck

-level areas in which to operate

-edge protection

-other vehicular movements

-custody of detonators

-custody of primers

-number of persons present

-size of safety area

-awareness of danger zone

-availability of Manager

-means of communication

-mobile signal strength

-material spillage

-electromagnetic hazards

-lightning awareness

There may be other hazards ( eg weather)

The check list approach is beneficial for a number of reasons, It confirms that the predelivery requirements are met before dispatching the vehicle. These include elements such as having an adequate face profile, confirming the calibration of profiling and shotfiring equipment, availability and validity of site mixing licences and Site Managers Rules, critical safety checks in date etc. It also focuses the crews' attention on safety, as it is they who should conduct an "Onsite Risk Evaluation".

On arrival at the site, and during the transit to the face/ judgements are made on the hazards present such as accessibility, visibility, edge protection etc. Should the risk presented by any element at the place of use be unacceptable to the bulk truck crew, they should discuss the issues immediately with their own management and the Site Management.

In a similar way a protocol may be required for production and loading. This protocol may contain the following items:

-Kind of explosives that are produced

-Number of boreholes and the rows

-Loading mass for every borehole

-Need of intermediate stemming

-Explosive running out of borehole

-Density control

-Matrix temperature

-Dry or wet borehole

-Any other comments

Training of quarry personnel

When changing to pump emulsion the quarry personnel have to be trained and advised well before the first blast is made.

Minimum subjects that should be included are the explosives characteristics, blast design (changes evaluated from customer and deliverer to obtain a safe and economic result), a method statement and safety data sheets.