The NSW Resources Regulator has issued a safety alert after a worker suffered partial amputation of three fingers during maintenance at a mine site, warning against line-of-fire exposure and the use of improvised electrical systems.
The incident occurred while a team was lowering a water cart tank following a torque converter seal replacement. With the tank lift system disabled and a faulty level sensor preventing normal operation, workers used a drill battery and short wires to energise a hydraulic solenoid. The hydraulic ram retracted unexpectedly, trapping the worker’s hand beneath the running machine.
Following the incident, the regulator issued prohibition notices banning improvised and portable power supplies and restricting workers from entering the footprint of live mobile plant during testing or inspection, unless strict procedural and supervisory controls are in place.
The alert urges mine operators to eliminate uncontrolled powered testing and formalise “machine under test” procedures. These procedures must define when powered work is necessary, outline safe methods, and reflect the significant risks involved.
The regulator recommends that powered testing only occur using approved, engineered tools and systems designed to allow remote activation and exclude workers from line-of-fire zones. Physical barriers and isolation measures should be standard unless risk-based exceptions are formally approved.
Electrical safety requirements must also be tightened. Any portable energy systems must be designed and used only by competent personnel, approved by a statutory electrical engineer, and supported by clear documentation.
The alert further calls for maintenance systems to promptly fix critical defects that could drive unsafe workarounds, and for supervisors to actively verify task planning, electrical compliance, and control measures.
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