SITE SAFETY INNOVATION AWARDS
Innovation Title: Extension Step Locomotive R1004
Output Team/MRU:Railway Workshop, Andoom Operations
Person(s) Contributing:Adriaan Van Der Veen, Mechanical Apprentice Bernie Russ, Electrical Fitter
Michael Forde, Acting Crew Leader and Electrical Fitter
Implementation Date: May 2005
PROBLEM
A previous site safety incident involved a Locomotive Driver dismounting a stationary locomotive via the established exit point and losing his balance, falling heavily on his right leg. The incident resulted in a lost time injury.
The team completing the incident investigation identified that the distance between the ballast (ground surface) and the locomotive entry/exit point was too high, requiring the driver to take a larger step than normal when accessing/egressing the locomotive. The risk of a slip or fall was increased due to the nature of the bauxite ballast, which is a very uneven, unstable surface that can be slippery. A key recommendation arising from the investigation was that an appropriate access/egress system should be fitted to the locomotive to improve the ease and safety of locomotive access/egress, ultimately preventing a similar incident from occurring.
Key issues with the fitting of an access/egress system to the locomotive were as follows:
- The system must be able to be retracted when not in use to prevent contact/collision with objects alongside the track.
- The system needed to be easy to operate and maintain.
- The system needed to suit key users.
SOLUTION
Several members of the Railway Workshop crew, Adriaan Van Der Veen, MichaelForde and Bernie Russ, were tasked with identifying, designing and installing a suitable step access system for the locomotive. It was essential the step did not create any further hazards and be of sufficient strength/rating to be used by drivers of different heights and weights. The resulting safety innovation, the Extension Step Locomotive R1004, was implemented in May 2005. Advice from site engineering services and consultation with the Health and Safety team were sought when required.
The step extension allows the user to safely and easily move between the ballast and the locomotive. The step is pneumatically operated with electrical control, and can be controlled via push buttons located on the locomotive footplate and at ground level. When the locomotive is to be moved, the step must be folded in the up position. If the step is down the locomotive will not get tractive power. Should the step fail in the down position an electrical bypass switch can be used, so the locomotive can be used. The step can then be mechanically forced to the up position using a lever.
BENEFITS
The benefits of the extension step are summarized as follows:
- Distance between the ballast and locomotive is significantly reduced, improving locomotive access/egress, particularly when the locomotive pulls up on uneven ground.
- The extension step successfully addresses the root cause of a significant safety incident.
- The step is easy to engage and disengage (fold up), via push buttons located on both the locomotive footplate as well as at ground level.
- If the step is engaged the locomotive cannot move, which eliminates the possibility of someone accessing the step whilst the locomotive starts to move, as well as preventing the stair from contacting an obstruction whilst the locomotive is moving.
- Should the step fail whilst engaged, there is a bypass switch located in the cab that enables the locomotive to move once the steps are manually folded up via a lever.
- The step has been reviewed by a site Mechanical Engineer who has approved its load rating for a maximum of 90kg.
TRANSFERABILITY
The innovation could easily be transferred to rail operations in other industries. The design principles could also be used in any situation where it is necessary to fold away/retract a mechanical item.
INNOVATION
The Rail Workshop crew was responsible for all aspects of the design and installation process for the extension stair, including involvement in the management of change risk assessment process, conducting a trial amongst locomotive drivers and development of training guidelines and maintenance schedule. Refer to Appendix B for design schematics.
APPLICATION OF RISK MANAGEMENT PRINCIPLES
The extension step innovation is an engineering control.
Prior to the extension step becoming operational, the Rail Workshop crew undertook an extensive management of change process. This involved the following:
- Completion of a risk assessment. The risk assessment identified the presence of pinch points at the front of the steps. The team controlled this hazard by engineering two guards to be placed over the pinch points (refer to Appendix A for pictures). The team also recognized that because the step is not in the line of sight whilst folded up, yellow/black reflective caution tape needed to be applied to improve visibility.
- In order to determine the innovation was mechanically sound, engineering had to qualify the step as mechanically sound, calculations were completed to ensure the locking mechanisms could withstand the weight of a 90kg person exerting a force at approximately 60 degrees.
- A training package has been devised to inform all relevant personal of the operation and maintenance requirements of the extension step.
- Collection of anecdotal feedback from drivers and rail workshop personnel regarding their perceptions of the usefulness and safety aspects of the innovation.
- Obtained management approval for the use of the innovation.
APPENDIX A
APPENDIX A: INNOVATION PHOTOGRAPHS
APPENDIX B
APPENDIX B: DESIGN SCHEMATICS
Comalco Aluminium Ltd Weipa‘If it’s not safe, don’t do it that way’1