Good Practice

The company suffered a series of accidents and incidents related to crushers, where multi-level configurations played a significant role. Recognizing this, we prioritized eliminating multi-level designs around new install crushers. Additionally, simplifying access around crushers enhances maintenance and inspection processes.

The approach was rooted in the ERICP principle: by eliminating common hazards around crusher installations, we can significantly reduce the likelihood of slips, trips, or falls.

The single-level design concept can be extended to other areas of process plant design where access is restricted or obstructed. This approach has already been shared within the business

Please see additional pdf for details of the management and design process

Benefits:

• Safety: Having a single-level access ensures that operators and maintenance personnel can move around the crusher without encountering steep steps, uneven surfaces, or multiple levels.
• Efficiency: Single-level access streamlines operations. Operators can quickly reach critical areas such as the feed hopper, discharge chute and control panels. This reduces downtime and allows for smoother material handling.
• Maintenance: During routine inspections, repairs, or component replacements, a single-level layout simplifies access. Maintenance crews can easily reach all parts of the crusher, including wear liners, bearings, and belts. This promotes timely servicing and prolongs equipment life.
• Accessibility: A single-level design accommodates equipment such as cranes, lifting devices, and tools. These are essential for tasks like changing crusher liners or addressing mechanical issues. Having unobstructed access ensures efficient maintenance and prevents delays.