The innovation, developed by supervisors at the Rio Tinto opencut mine, was recognised last week by the NSW Minerals Council and was awarded the Occupational Health and Safety Innovation Award – 2005.

The solution was engineered to overcome the problems associated with a build-up of stored energy in equipment used to apply lubrication. In 2004, a mine worker lost an eye as a result of fluid injection – when pressure turns a pinhole leak of fluid into a “laser beam” style-cutting instrument measuring up to 10,000psi.

Normal methods of applying lubrication to equipment require the use of pressure to force the lubricant through a small aperture. The problem occurs when force is applied to a liquid, with the liquid itself able to act as a force that can easily be multiplied to create tremendous pressures.

Pressures can build up in the lubrication chamber to extremely high levels and present a hidden stored energy potential. In addition, trapped air can be compressed, making the release more violent and dangerous.

Stored energy in equipment can remain undetected and has resulted in significant personal injury to people when dismantling components.

Workers involved in system maintenance at Mt Thorley could not determine the potential for stored energy, and did not have a simple and effective method for reducing stored energy.

A small team was charged with finding a solution and came up with a new device that has been successfully trialled. The result is a $A400, handheld tool that has eliminated the potential for the unexpected release of stored energy on greasing systems. Workers now have a simple and effective calibration check on the tool prior to and during use.

In the submission document for the award, Rio Tinto said a key determinant of the innovation’s success was if it met employees’ expectations as to the device’s practicality.