RA - MILL RELINING Revised

EPC TASK RISK ANALYSIS AND SAFE WORK PROCEDURE REFERENCE:
WESTERN PLATINUM LIMITED

Metallurgical Plant EPC Concentrator EPC001
OCCUPATION: General F/Man, Plant FACILITATOR: Athol Ballot MEMBER 3: APPROVED BY: DATE COMPILED: 04/07/2008
F/Mans, P/Controller, Elect F/Man & Mech F/Man Mapingana, Wycliffe
OCCUPATION CODE: MEMBER 1: MEMBER 4: SIGNATURE: REVISION NUMBER:
C.P. van der Vyver Barries Barnard 1

AREA:EPC Plant MEMBER 2: MEMBER 5: DATE: REVISION DATE:
Mill Relining Seun Fernandez Wilhelm Prinsloo (Mac Jay) 29/04/2009
INDEX TASK OR ACTIVITY DESCRIPTION TASK NO. BASIC SEQUENCE/TASK/JOB STEPS POTENTIAL AND EXISTING HAZARDS RISK EVALUATION CORRECTIVE MEASURES & CONTROLS
LIST ALL THE TASKS DONE OR THAT MIGHT BE DONE SAFETY - INJURY EXPOSURES (EYES, HANDS, FEET, ETC.)
BY A PERSON IN THIS OCCUPATION HEALTH - NOISE, HEAT, CHEMICALS, STRESS, DUSTS, FUMES, COLD, BOILOGICAL, VIBRATIONS, ETC.
PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.
ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING
1.0 Get Tools and equipment 1.1 Air impact machine,16Lbs 1.1.1 Hand injuries 2 2 -1 3 1.1.1 Wear Safety gloves,Safety shoes and Hard hat
&4LbsHammers.Punches,Pinchbars,Slings and
liners and bolts.
2.0 Mill Relining 2.1 Arrange for mill to be locked out by Plant 2.1.1 Electrical flash 4 1 -1 4 2.1.1 Stop mill motor and follow HT - lockout procedure
Electrician
2.1.2 Electrical shock 4 1 -1 4 2.1.2 Stop mill motor and follow HT - lockout procedure
3.0 Engage barring gear 3.1 Bar mill 3.1.1 Moving machinery 4 2 -1 5 3.1.1 Ensure siren is sounding and nobody is inside or
on top of mill.Ensure barring gear is engaged
properlyand people away from mill at nip
points.Ensure good communication and have
constant observation
3.1.2 Noise (alarm) 2 3 -1 4 3.1.2 Ensure correct ear protection is used and that
everybody is adhering
4.0 Remove liner bolts on door 4.1 Use hammer,impact machine and pinchbar 4.1.1 Moving machinery 2 2 -1 3 4.1.1 Make sure impact tools is on inspection list and
list is up to date.Pre-use inspection carried out
and impact machines in good working order.Make
sure there are no sharp edges on sockets.Make
sure socket is secured to machine in the correct
manner
4.1.2 Falling objects 2 2 -1 3 4.1.2 Use PPE:Hard hat,Overall,Safety boots and

Safety gloves
4.1.3 Working at hieghts 4 2 -1 5 4.1.3 Make sure people ontop of mill wear safety
harness and is connected to lifeline
4.1.4 Splintering of bolts and dust 2 2 -1 3 4.1.4 Use correct PPE(Safety gloves,Safety goggles
and Hard hat
5.0 Remove door 5.1 Use O/head crane and sling 5.1.1 Rigging by crane /Rigging can let go 4 1 -1 4 5.1.1 Rigging only to be done by licenced personell and
with registered equipment
6.0 Remove liners from position 6.1 Loose liners to be removed 6.1.1 Falling and flying objects 1 2 -1 2 6.1.1 Make sure nobody is inside mill when bolts is
removed .Work on one loose liner at a time,other
to have at least one bolt left in place
6.1.2 Falling steelballs and dust 1 2 -1 2 6.1.2 Wear eye protection and hardhat
6.1.3 Slipping and falling 1 2 -1 2 6.1.3 Wear safety boots and level ball load before
working in mill
6.1.4 Hazzard caused by cutting torch 3 1 -1 3 6.1.4 See cutting torch risk assessment. Dust extraction
fan
6.1.5 Lack of light 1 2 -1 2 6.1.5 32Volt hand held light
6.1.6 Poor ventilation 2 2 -1 3 6.1.6 Install fan at mill inlet
6.1.7 Heat 3 2 -1 4 6.1.7 Install fan at mill inlet / Make use of respirator
6.1.8 Flying objects 2 2 -1 3 6.1.8 Make use of PPE
S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss
No injury/illness or quality, production or
0 - other loss <R10000 4 - Very Serious: One fatality or damage over R1 000 000 Dependant on both the number of personsinvolved and the number of times the task is -1 Less than average probability of loss
Of Concern: Minor injury/illness or damage Once per week with only 1 to 3 persons
1 - over R1000 5 - Disaster: A few fatalities or damage over R10 000 000 1 - performing the task. 0 Average probability of loss (50/50 chance)
Important: Temporary disability or damage On average daily with 3 to 5 persons performing
2 - over R10 000 6 - Catastrophic: Many fatalities or damage over R100 000 2 - the task. +1 Greater than average probability of loss
Serious: Seious injury or damage over Many times daily with 5+ persons performing the
3 - R100 000 3 - task.


5 7.1.1 Gloves,overall,safety shoes,sound judgement and
7.0 Remove liners 7.1 By hand 7.1.1 Pinching and nipping of body parts 3 2 0 the use of pinchbars
7.1.2 Incorrect lifting posture 3 2 0 5 7.1.2 Lift liners using correct body posture
7.1.3 Falling objects 2 2 -1 3 7.1.3 Hardhat and barricade area under mill when
throwing out liners
7.1.4 Heights 4 2 -1 5 7.1.4 Work from inside mill and stand on
platform(Grating floor)
7.2 By overhead crane 7.2.1 Hazzards from rigging by crane 4 1 -1 4 7.2.1 Rigging only to be done by licenced personell and
with registered equipment
8.0 Prepare to replace liners 8.1 Clean inside mill at liner position 8.1.1 Flying particles 2 2 -1 3 8.1.1 Use eye protection
8.1.2 Nipping of body parts 3 2 0 5 8.1.2 Use safety gloves
9.0 Prepare mill shell 9.1 Rubber lining 9.1.1 Hazzards from rubberlining 5 1 0 6 9.1.1 Use air grinder and adequote ventilation by fan
9.1.2 Toxic fumes 4 1 -1 4 9.1.2 Use only 32volt hand held light and only specified
solution,glue,hardner and cleaning solvents
10.0 Prepare to reline 10.1 Feed liner into mill by hand 10.1.1 Pinching and nipping of body parts 3 2 0 5 10.1.1 Gloves,overall,hardhatand safety shoes
10.1.2 Incorect lifting posture 3 2 0 5 10.1.2 Lift liners using the correct body posture
10.1.3 Falling objects 2 2 -1 3 10.1.3 Gloves,overall,hardhatand safety shoes
10.1.4 Heights 4 2 -1 5 10.1.4 Work from inside mill and stand on platform
Grating floor
10.2 Feed liners into mill by crane 10.2.1 Hazzards from rigging by crane 4 1 -1 4 10.2.1 Rigging only to be done by licenced personell and
with registered equipment.NB.Crane driver to
alert people inside mill
11.0 Fit liners 11.1 Install liners in position 11.1.1 All hazzards as remove liners by hand 3 2 0 5 11.1.1 Gloves,overall,safety shoes,sound judgement and
the use of pinchbars
11.1.2 Nipping of body parts 3 2 0 5 11.1.2 Gloves,overall,safety shoes,sound judgement and
the use of pinchbars
11.1.3 Falling liners 4 2 0 6 11.1.3 Install 1 liner at a time and make sure that liner is
fastened properly
11.1.4 Beware of protuding pinchbars when liners are 4 2 0 6 11.1.4 Positioning of people outside Mill when liners are
fitted to the Mill fitted

0 - other loss <R10000 4- Very Serious: One fatality or damage over R1 000 000 Dependant on both the number of personsinvolved and the number of times the task is -1 Less than average probability of loss
1 - over R1000 5- Disaster: A few fatalities or damage over R10 000 000 1 - performing the task. 0 Average probability of loss (50/50 chance)
2 - over R10 000 6- Catastrophic: Many fatalities or damage over R100 000 2 - the task. +1 Greater than average probability of loss
3 - R100 000 3 - task.


11.0 Fit Liner 11.1 Install liner in position 11.1.4 Moving machinery 4 2 -1 5 11.1.4 See Procedure for impact tool
11.1.5 Hazzards surrounding impact tool 4 2 -1 5 11.1.5 See Procedure for impact tool
11.1.6 Heights 4 2 -1 5 11.1.6 Make use of safety harness and lifeline
11.1.7 Falling nuts and washers 2 2 -1 3 11.1.7 Wear hardhat
12.0 Replace mill door 12.1 Refit mill door 12.1.1 Same as for removing mill door
13.0 Relining completed 13.1 Swirch mill on in substation 13.1.1 Electrical flash 4 1 -1 4 13.1.1 Work according to HT - lock out procedure
14.0 Reline feed end and screens 14.1 All steps as obove
14.2 Cut rubber to size if not perfect fit 14.2.1 Cut wounds on body parts 4 1 0 5 14.2.1 Make use of safety gloves and make use of
sound safety judgement

0- other loss <R10000 4- Very Serious: One fatality or damage over R1 000 000 Dependant on both the number of personsinvolved and the number of times the task is -1 Less than average probability of loss
1- over R1000 5- Disaster: A few fatalities or damage over R10 000 000 1 - performing the task. 0 Average probability of loss (50/50 chance)
2- over R10 000 6- Catastrophic: Many fatalities or damage over R100 000 2 - the task. +1 Greater than average probability of loss
3- R100 000 3 - task.

1.0 Use of impact tool 1.1 Connect air hose to air valve and impact machine 1.1.1 Leaks on air hose 2 1 0 3 1.1.1 Inspect air hose for leaks using your senses
1.1.2 Live air hose become loose 3 1 0 4 1.1.2 Make use of swing check
1.1.3 Air pipe burst 2 1 -1 2 1.1.3 Inspect air hose for weak points
2.0 Alighn impact tool with bolt 2.1.1 Nipping of body parts 1 2 -1 2 2.1.1 Use safety gloves
2.1.2 Inadvertand triggering of tool before socket 1 1 -1 1 2.1.2 Training on correct usage of impact tool
alighned over nut
3.0 Securing socket to tool 3.1.1 Falling objects 2 2 -1 3 3.1.1 Use delpin and O-Ring to secure socket
4.0 Operating impact tool 4.1.1 Falling from heights 4 2 -1 5 4.1.1 Lifeline,Relining platform(grating floor),Also make
sure footing is secure.Also make sure usage of
safety harness
5.0 Close air supply to impact machine 5.1.1 Removing of air pipe pre-maturily 4 2 -1 5 5.11 Make sure air pressure is released
6.0 Disconect airpipe from impact tool 6.1.1 Pressurised air hose 3 1 0 4 6.1.1 Release pressure in line before removing air pipe
from impact tool

3- R100 000 3 - task.
Metallurgical Plant EPC Concentrator

EPC001

1.0 Use of barring gear 1.1 Lock out Mill 1.1.1 Electrical flash 4 1 -1 4 1.1.1 Mill to be locked out according to HT - lock out
procedure
1.2 Swing away safety catch 1.2.1 Nipping of body parts 1 1 -1 1 1.2.1 Wear safety gloves and use caution and be alert.
1.3 Align coupling teeth 1.3.1 Damage to gear teeth 2 1 -1 2 1.3.1 Use cation that gears do not touch before
alighned. Competent person, according
toprocedure. Watch for limit switches.
1.4 Engage barring gear 1.4.4 Nipping of body parts 1 1 -1 1 1.4.4 Use caution and be alert when engaging barring
gear. Competent person, according toprocedure.
Watch for limit switches.
1.5 Swing back safety catch 1.5.1 Nipping of body parts 1 1 -1 1 1.5.1 Wear safety gloves and use caution and be alert.
Competent person, according toprocedure. Watch
for limit switches.
1.6 Check brakes against uneven load 1.6.1 Brake failure can result in disintegration of motor 4 1 0 5 1.6.1 Test barring gear brake before commencing
relining. Procedure to be followed.
1.7 Bar mill and even load 1.7.1 None 1.7.1 Use caution and be alert
1.8 Swing away safety catch 1.8.1 Nipping of body parts 1 1 -1 1 1.8.1 Wear safety gloves and use caution and be alert.
Competent person, according toprocedure. Watch
for limit switches.
1.9 Disengage barring gear 1.9.1 Nipping of body parts 1 1 -1 1 1.9.1 Use caution and be alert. Competent person,
according toprocedure. Watch for limit switches.
2.0 Swing back safety catch 2.0.1 Nipping of body parts 1 1 -1 1 2.0.1 Wear safety gloves and use caution and be alert
2.1 Barring gear to be locked out and keys to be in 2.1.1 Can be barred when somebody in mill 2 1 -1 2 2.1.1 Lock out Barring gear
box Al partisipants to lock out on box
2.2 Switch mill on in substation 2.2.1 Same as for lock out mill
2.2.2 People still on mill or inside mill 4 1 -1 4 2.1.2 Follow lock out procedure and make sure all
people are off and out of mill
2.2.3 Tools still on mill 2 1 -1 2 1.1.3 Make sure all tools and equipment are removed
on or inside mill

3- R100 000 3 - task.

EPC001

1.0 Operate Overhead Crane 1.1 Fetch pendant in workshop and sighn in register
1.2 Check hook condition 1.2.1 Snagging of rope & safety catch 2 1 -1 2 1.2.1 Monthly and pre - use inspection
1.3 Put crane in correct position 1.3.1 Damage due to crane not over item lifted 2 1 -1 2 1.3.1 Use skilled people.Only persons with a valid
crane licence to operate crane
1.4 Use lifting lugs on sling.(Shackles) 1.4.1 Rigging can let go 3 1 -1 3 1.4.4 Check sling placement on hook
1.5 Keep people away 1.5.1 Lifted liners can fall or sway 3 1 -1 3 1.5.1 Trained people to do rigging
1.6 Place liners in side mill or on floor 1.6.1 If not proprerly guided load can unhook 3 1 -1 3 1.6.1 Name specific person to do guiding. Responsible
person, artisan to give signals.
1.7 Keep pendant in hand 1.7.1 Pendant can be damaged 1.7.1 Register to monitor abuse of pendant
1.8 Pendant back to workshop after completion of
work and sighn off register

0 - other loss <R10000 4- Very Serious: One fatality or damage over R1 000 000 Dependant on both the number of personsinvolved and the number of times the task is -1 Less than average probability of loss
1 - over R1000 5- Disaster: A few fatalities or damage over R10 000 000 1 - performing the task. 0 Average probability of loss (50/50 chance)
2 - over R10 000 6- Catastrophic: Many fatalities or damage over R100 000 2 - the task. +1 Greater than average probability of loss
3 - R100 000 3 - task.

EPC001

1.0 Oxy-Ace Cutting 1.1 Do pre use inspection 1.1.1 Gas can ignite 3 1 -1 3 1.1.1 Pre use inspection to be carried out
1.2 Bottles to be in cage or secured on trolley 1.2.1 Bottles can fall over 2 1 -1 2 1.2.1 Use cage or secure with rope
1.3 Bottles to be upright 2 1 -1 2
1.4 Have the correct full fire extuinguisher at bottles 1.4.1 There are a fire risk when cutting with flame 1 2 -1 2 1.4.4 Have fire extinguisher available
1.5 Use leather gloves and cutting goggles 1.5.1 Spark & slag burns on hands and in eyes 2 1 -1 2 1.5.1 Wear safety gloves and use caution and be alert
as well as cutting goggles.(PPE)
1.6 Clear area of things that can burn 1.6.1 Fire / Explotion 2 1 -1 2 1.6.1 Clear area before work
1.7 Check area for any flames on completion of 1.7.1 A fire could start from smouldering line gaskets 1 1 -1 1 1.7.1 Hose area if required
cutting

3- R100 000 3 - task.
KAREE MINE TASK RISK ANALYSIS AND SAFE WORK PROCEDURE REFERENCE:
Metallurgical Plant (MIX & UG2) CTF03
OCCUPATION: FACILITATOR: MEMBER 3: APPROVED BY: DATE COMPILED:
AREA: MEMBER 2: MEMBER 5: DATE: REVISION DATE:

0 - No injury/illness or quality, production or other loss <R10000 4 - Very Serious: One fatality or damage over R1 000 000 Dependant on both the number of personsinvolved and the number of times the task is performed -1 Less than average probability of loss
1 - Of Concern: Minor injury/illness or damage over R1000 5 - Disaster: A few fatalities or damage over R10 000 000 1 - Once per week with only 1 to 3 persons performing the task. 0 Average probability of loss (50/50 chance)
2 - Important: Temporary disability or damage over R10 000 6 - Catastrophic: Many fatalities or damage over R100 000 000 2 - On average daily with 3 to 5 persons performing the task. +1 Greater than average probability of loss
3 - Serious: Seious injury or damage over R100 000 3 - Many times daily with 5+ persons performing the task.
Karee Mine
TASK INVENTORY RISK MEASUREMENT INDEX
SEVERITY ( Worst case scenario if hazard should realize )

Index
Value
Catastrophic ( many fatalities or damage over R100 000 000 ) 6
Disaster ( a few fatalities or damage over R10 000 000 ) 5
Very Serious ( one fatality or damage over R1 000 000 ) 4
Serious ( serious injury or damage over R100 000 ) 3
Important ( temporary disability or damage over R10 000 ) 2
Of Concern ( minor injury or damage over R1 000 ) 1
REPETITIVENESS ( How often is the task performed )
Number of Number of times the task is performed by each person

persons performing Occasionally Frequent Continues
the task ( Less than Daily ) ( Once daily ) ( Many times Daily )
Few ( 1-3 ) 1 1 2
Moderate ( 4-5 ) 1 2 3
Many ( 6 and more ) 2 3 3
PROBABILITY ( Chance of loss / harm during the exposure period )

Index
Value
Less than average probability of loss (has happened somewhere) -1
Average probability of loss (50/50 chance) 0
Greater than average probability of loss +1

(most likely and expected result if event occurs)
RISK RESULT = SEVERITY + REPETITIVENESS + PROBABILITY

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EPC TASK RISK ANALYSIS AND SAFE WORK PROCEDURE REFERENCE:

WESTERN PLATINUM LIMITED

C.P. van der Vyver Barries Barnard 1

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

4.1.2 Falling objects 2 2 -1 3 4.1.2 Use PPE:Hard hat,Overall,Safety boots and

EPC TASK RISK ANALYSIS AND SAFE WORK PROCEDURE REFERENCE:

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

EPC TASK RISK ANALYSIS AND SAFE WORK PROCEDURE REFERENCE:

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

Metallurgical Plant EPC Concentrator

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

Metallurgical Plant EPC Concentrator

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

Metallurgical Plant EPC Concentrator

PROCESS - WASTE, DOWNTIME, EQUIPMENT FAILURE, QUALITY, ETC.

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

OCCUPATION CODE: MEMBER 1: MEMBER 4: SIGNATURE: REVISION NUMBER:

AREA: MEMBER 2: MEMBER 5: DATE: REVISION DATE:

ENVIRONMENT - HAZARDOUS WASTE, OIL, THINNERS, ETC. S R P RATING

S - Severity (1 = minor 6 = very serious) R - Repetitiveness (1 = occasional 3 = often) P - Probability of Loss

TASK INVENTORY RISK MEASUREMENT INDEX

SEVERITY ( Worst case scenario if hazard should realize )

Catastrophic ( many fatalities or damage over R100 000 000 ) 6

Disaster ( a few fatalities or damage over R10 000 000 ) 5

Very Serious ( one fatality or damage over R1 000 000 ) 4

Serious ( serious injury or damage over R100 000 ) 3

Important ( temporary disability or damage over R10 000 ) 2

Of Concern ( minor injury or damage over R1 000 ) 1

REPETITIVENESS ( How often is the task performed )

Number of Number of times the task is performed by each person

PROBABILITY ( Chance of loss / harm during the exposure period )

Less than average probability of loss (has happened somewhere) -1

Average probability of loss (50/50 chance) 0

Greater than average probability of loss +1

RISK RESULT = SEVERITY + REPETITIVENESS + PROBABILITY

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