The COP must set out how the significant risks identified in the risk assessment process referred to in paragraph seven above will be addressed. The COP must cover at least all the aspects set out hereafter unless there is no significant risk associated with that aspect at the mine.
8.1 Design and specification
In order to ensure that all RBE is appropriate for the specific circumstances at the mine and is used within its designed and operating specifications, the COP must describe the following information.
| 8.1.1 | Rail Bound Equipment (RBE) |
Provide a detailed table containing the following information as a minimum for all locomotives in use,
| (a) | Prime mover (electrical, battery, diesel etc.). |
| (b) | Rated capacity of each locomotive. |
| (c) | Original Locomotive Equipment Manufacturer (OEM). |
| (d) | Locomotive controller make and model. |
| (e) | Maximum design tramming capacity (tons). |
| (f) | Maximum designed speed (kilometres/hour). |
| (g) | Maximum designed operating gradient (degrees to the horizontal). |
| (h) | Gross mass in kilograms. |
| (i) | Overall dimensions including battery if applicable (millimetres), |
| (j) | Designed rated power (kiloWatt). |
| (k) | Manual, remote or remotely controlled. |
| (l) | Types of brakes (S= service, P = park, E = emergency). |
| (m) | Proximity detection system. |
Braking systems
List and describe in detail the braking systems installed on all locomotives, including but not be limited to, the design, specification and method of the application:
| (d) | Any combination of a, b and c above. |
8.1.1.2 Rolling stock
List and describe for each type, make and class of each item of rolling stock the following information as a minimum.
| (a) | Type (hopper, material car, etc.). |
| (b) | Capacity (kilogram, number of persons, pipes, rails in bogies etc.). |
| (c) | Overall dimensions without buffers. |
| (d) | Overall dimensions with buffers. |
| (e) | Buffer design (link and drop pin, automatic coupler, etc.). |
| (f) | Buffer height measured from top of rail to centre of buffer (mm). |
| (g) | Wheel base dimensions (millimetre). |
| (h) | Fixed continuous drawbar attached between buffers (yes or no). |
| (i) | In the case of hoppers, the method of discharge. |
8.1.1.3 Rail bound cycles
Where persons are transported by means of rail bound cycles, describe the following:
| (a) | Approved design and construction of cycle; |
| (b) | Effective braking requirements; |
| (c) | Proper seating arrangements to prevent standing of persons during transport; |
| (d) | The number of persons allowed to travel on the cycle; |
| (e) | Audible warning device to warn other RBE users in the vicinity; and |
| (f) | Measures to ensure visibility of the cycle. |
8.1.2 Rail infrastructure
List and describe the following information as a minimum:
Rail track installation
(a) Rail mass (kilogram per metre);
(b) Rail gauge and tolerances (millimetre);
(c) Rail sleeper types (wood, concrete steel etc.);
(d) Rail sleeper spacing standards (millimetre);
(e) Fish plate type and design;
(f) Method of securing rails to sleepers (e-type, dog spike etc.);
(g) Welding of rails joints if applicable;
(h) Maximum permissible rail joint gaps (millimetre);
(i) Maximum permissible rail joint horizontal alignment (millimetre);
(j) Maximum permissible rail joint crown height difference (millimetre);
(k) Provisions for drainage;
(l) Ballast type;
(m) Rail switch type (single tongue, double blade etc.);
(n) Rail switch methods of operation (tumbler, lever etc.); and
(o) Rail switch dimensions (millimetre).
Rail traversers
Describe the design and layout for rail traversers, where used, to permit only one item of RBE at a time to pass over the traverser car.
8.1.3 Haulages and associated infrastructure
Describe, taking into account ergonomic principles where appropriate, the design and layout of underground haulages and associated infrastructure where RBE is used, including the following aspects:
| (a) | Safe-guarding of persons against accidental contact with RBE; |
| (b) | Station lay-out including types, configurations and methods of activation of arresting devices, their rated energy absorption capacities and any other provisions for arresting RBE and trackless mobile machines (TMM) inadvertently entering shaft station areas; |
| (c) | Boarding and alighting platforms for persons; |
| (d) | Battery bays including provisions for changing batteries; |
| (f) | Ore loading facilities; |
| (g) | Diesel refuelling bays; |
| (h) | Timber bays, waiting places and any other similar excavations in immediate proximity to the rail track infrastructure; |
| (i) | Illumination including light intensity, type, spread and range of light beams; |
| (j) | Overhead trolley line infrastructure; |
| (k) | Crossings where RBE and TMM interface; |
| (l) | Warning sirens and alarms; and |
| (m) | Signage including speed restrictions, restricted areas, loading and tipping areas, no entry signs to unauthorised persons, work in progress, electrical equipment, etc. |
8.1.4 Tipping arrangements
Describe the design, configuration and layout of tipping arrangements, including the following:
| (a) | Method of discharge operation (e.g. side tipping, bottom discharge); |
| (c) | Safeguarding of persons from falling into ore passes or being struck by falling rock by provision of safety devices such as safety belts, lockout facilities, closing or opening of ore passes when tipping is not in progress; |
| (e) | Provisions for the control of water in the tipping area; |
| (f) | Facilities for the re-railing of RBE inside tipping areas; and |
| (g) | Provisions for the safe passage of pedestrians. |
8.2 Operational Requirements
The COP must describe measures to ensure that the manner in which RBE is operated is such that the significant risks are minimised, which measures must include at least the following:
8.2.1 Traffic management plan
The traffic management plan should include the following:
| (a) | Safe start-up, operation, parking, shut-down, loading, securing and prevention of unauthorised access of RBE; |
| (b) | Isolation and lockout requirements (mechanical, electrical, hydraulic, pneumatic, radio frequency, etc.); |
| (c) | Areas where people are travelling, including traffic control, speed and clearance restrictions; |
| (f) | Transport of persons, materials, minerals, explosives, hazardous chemical substances, abnormal loads, long material, special purpose cars, loaders, etc.; |
| (i) | Safe tramming of RBE through obstructions such as ventilation doors and other restricted areas such as regulators, fire doors, bull noses, water doors, battery bays, workshops, fuelling stations, waiting stations as well as blind curves or restricted operator visibility, etc; |
| (j) | Demarcation of restricted areas where clearances are not met; |
| (k) | The protection of driver, guard and other persons during transport activities; |
| (l) | Recording and reporting of any failures, incidents or derailments involving RBE affecting health and safety; |
| (m) | Transport of tools and equipment permitted on the locomotive and guard car; |
| (n) | The safe remote operation of a locomotive or train that is remotely operated; |
| (o) | The safe operation of any manually operated switch on any track from a safe position clear of the track by means of a suitable tool or device; |
| (p) | Measures to prevent inadvertent run-away of a locomotive or train; |
| (q) | Remote or manual operating methods of ventilation doors; |
| (r) | Fouling marks to indicate switches, etc.; |
| (s) | Emergency procedures including the procedure in case of lamp or luminaire failure; |
| (t) | Overhead trolley line systems; |
| (u) | Operation of proximity detection systems, where applicable; |
| (v) | Coupling and uncoupling of RBE; |
| (w) | Communication protocols between operators, guards and pedestrians; |
| (x) | The testing of braking systems; |
| (y) | Pre-use checklist implementation; and |
| (z) | Interaction right of way protocols between RBE and TMM. |
| 8.2.2 | Battery charging bays (where applicable) |
The COP must describe the procedures for the following:
| (a) | Charging of traction batteries. |
| (b) | Changing of traction batteries. |
| (c) | Actions to be taken in the event of a power failure. |
| (d) | Actions to be taken in the event of a fire. |
| (e) | Actions to be taken in the event of an acid spillage. |
| (f) | Actions to be taken in the event of a ventilation failure. |
| 8.2.3 | Diesel refuelling bays (where applicable) |
The COP must describe the procedures for the following:
| (a) | Transportation, storage and handling methods for diesel fuel. |
| (b) | Refuelling of diesel powered locomotives. |
| (c) | Actions to be taken in the event of a power failure. |
| (d) | Actions to be taken in the event of a fire. |
| (e) | Actions to be taken in the event of a diesel spillage. |
| (f) | Actions to be taken in the event of a ventilation failure. |
| 8.2.4 | Visibility of RBE and persons |
The COP must describe the methods and procedures for the use of road signs and warning devices, including at least the following:
| (a) | The placing of signs to warn persons against the presence of parked, stationary and broken down RBE; |
| (b) | Measures to ensure the visibility and safety of pedestrians, cyclists or other persons in the proximity of RBE; |
| (c) | Timeous warning systems, where persons are required to work in haulages where RBE is operated, for either the operator or such persons; and |
| (d) | Dust control so as not to impair visibility. |
| 8.2.5 | Safety devices and provisions |
The COP must describe the specifications and operation of signalling- and warning devices or provisions, including the following:
| (a) | Flashing lights on remote controlled locomotives for identification; |
| (b) | Warning lights when entering dangerous areas; |
| (c) | Tail lights on locomotives and guard cars indicating the direction of travel of RBE; |
| (d) | Clear markings, signage and demarcations indicating restricted areas where persons travel; |
| (e) | Audibility of bells or sirens for warning persons whilst travelling where RBE operates; |
| (f) | Overhead electric line warning signage; |
| (g) | Locomotive controller dead man's device; Dead man's device as defined in SANS 1809: 2003; |
| (h) | Signalling systems to clearly distinguish instructions; |
| (i) | Speed governors as a means of regulating speed where installed; |
| (j) | Where installed speed indicators for operators of RBE equipment to indicate actual speed; |
| (k) | Indications, signage and other warning provisions to the operators of RBE of any work being undertaken in the area of travel; |
| (l) | Traffic lights, and/or any other provisions to indicate the right of way for safe passage; |
| (m) | Where installed over-speed alarms to warn operators if speed is exceeded; |
| (n) | Communication systems between the locomotive operator and the guard for effective control and instruction; |
| (o) | The inspection and testing of all safety devices and provisions at intervals determined in the COP; and |
| (p) | Provisions for and means of extinguishing fires on trains. |
8.2.6 Rail bound cycles
The COP must describe standards and procedures for the safe operation of rail bound cycles.
8.3 Maintenance and modifications
The COP must describe measures to ensure that RBE is adequately maintained or modified covering at least the following:
The COP must describe the maintenance, over inspection requirements and frequencies for all types of RBE including methods of isolation and making safe of the RBE.
8.3.2 Rail track maintenance
The COP must describe the maintenance, over inspection requirements and frequencies for the rail track infrastructure.
8.3.3 Modifications to RBE
The COP must describe procedures for any modifications to RBE, addressing as a minimum, a risk assessment, record keeping of design and specification changes and updating of engineering drawings.
8.3.4 Procedure for the testing of braking systems
The COP must describe the methods and procedures for the testing of braking systems, including the following:
| (a) | Static testing of braking systems; |
| (b) | Dynamic type testing of braking systems to ensure the retardation rates required by Regulation 8.3.18 (see Annexure 1), which must be complied with; |
| (c) | Recording of the results of static and dynamic type tests; and |
| (d) | Safe keeping of test results, for a period to be specified in the COP. |
8.4 Personnel
The COP must describe the procedures for the selection, training, testing and associated record keeping for the operators of RBE, covering at least the following:
8.4.1 Selection criteria
Selection criteria for operators should prescribe the minimum standards in relation to the following:
| • | Hand - eye co-ordination; |
| • | Night or colour blindness; |
| • | Anthropometrics (size, height, mass, etc.). |
The COP must describe the methods, procedures and training to ensure that RBE is only operated by persons who are competent to do so.
8.4.3 Authorisation to operate RBE
The COP must describe the procedures for the appointment and authorisation of competent persons to operate RBE.
The COP must describe the procedures, methods and period of record keeping of all information associated with the training, declaring competent, authorisation and appointment of all RBE operators.
