25th Mechanical Engineering Safety Seminar

What does the future hold for mechanical

equipment?

25th Mechanical Engineering Safety Seminar Presented by: WJ Koppe – Inspector of Mechanical Engineering Resources and Energy – Mine Safety 9 & 10 September 2015

What does the future hold for mechanical equipment?

We expect equipment used at mines to: Become larger More complex Have lower factors of safety Have more sensors and warning devices Have automatic functioning Involve more electronics / computer control Require more specialised electrical and mechanical maintenance personnel Require more involvement of suppliers Be involved in future fatalities

What can be used to predict the probability of future fatalities?

A review of: Incidents including near miss events Accidents Equipment limitations Competence assessment Compliance to standards / guidelines Risk analysis / management Fatality database

What equipment has been involved in fatalities?

Surface mines and quarries Trucks Excavators Tyres Elevated Work Platforms Walkways Overhead Power lines

Underground Metal Mines

Winders Trucks Remote controlled LHD’s Raise Borer

Underground Coal Mines Gas ignitions from Brakes, friction, sparking

High Pressure hydraulics Canopies of Continuous Miners Canopies on LHD’s Drift Haulage Rail Haulage Conveyors Drill Rigs Vehicle Park Brakes

What suggests more winder fatalities may occur?

Recent incidents where winder ropes were substantially below the minimum factor of safety

A design issue where the brakes were inadequate because of reliance on braking effect of the worn reducer

The age of some of the equipment The lack of knowledge of some of the responsible

personnel The safety equipment / standards of some of the

equipment used for shaft sinking The need to have power on for some maintenance tasks The complexity of the systems

Winder Incidents

Year 2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Coal Mine

22

13

20

12

67

Metal Mines

2

7

1

3

13

Total

24

20

21

15

80

Coal U/G

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Southern mine A

4

2

4

4

14

Northern mine B

1

0

0

0

1

Western mine C

1

1

0

1

3

Northern mine D

0

0

1

0

1

Western mine E

1

0

0

1

2

Western mine F

3

0

6

0

9

Northern mine G

1

0

0

0

1

Western mine H

9

7

6

4

26

Western mine I

2

2

3

1

8

Northern mine J

0

1

0

1

2

Total

22

13

20

12

67

Winder Incidents

Metals U/G

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Metal mine A

2

2

0

0

4

Metal mine B

0

0

0

1

1

Metal mine C

0

2

0

0

2

Metal mine D

0

3

1

2

6

Total

2

7

1

3

13

Winder Incidents

Significant Winder Incidents Material falling down shafts during operation

– Head frame steelwork – Concrete from head frame – Skip wheel

Wet brakes Moisture in controls Travel in wrong direction Dump brake failures Failed to decelerate near end of wind Collision between skips Failure to enter guides Control failures Pre torque out of adjustment

What Suggests More Gas / Coal Dust Explosion Fatalities May Occur?

Gas trips Gas exceeding 2.5% Cable arcs Failure of explosion protection (Electrical) Failure of explosion protection (Diesel engines) Fires underground More conveyors and equipment in return airways Deeper mines / higher production Frictional ignition Spontaneous combustion Higher voltage equipment on longwalls Gas outbursts on the increase

Cable Arcs

Area North East South East Total

Incidents

168

89

257

Cable Arcs

Year 2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Incidents

70

64

70

52

257

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mine A 4 7 9 4 24

Mine B 2 4 0 3 9

Mine C 1 3 2 1 7

Mine D 2 2 3 4 11

Mine E 4 5 2 5 13

Mine F 2 0 1 1 4

Mine G 1 0 0 0 1

Mine H 1 1 3 2 7

Mine I 1 2 1 1 5

Mine J 3 2 2 0 7

Mine K 2 2 7 9 20

Mine L 2 0 2 1 5

Mine M 5 1 1 0 7

Mine N 3 3 2 1 9

Mine O 5 2 0 0 7

Cable Arcs

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mine P 1 1 0 1 3

Mine Q 11 9 10 13 43

Mine R 1 1 0 1 3

Mine S 5 4 13 2 24

Mine T 5 2 0 0 7

Mine U 0 5 0 0 5

Mine V 1 2 3 4 10

Mine W 0 0 2 0 2

Mine X 1 0 1 1 3

Mine Y 2 2 3 1 8

Mine Z 1 0 0 0 1

Mine AA 0 1 0 0 1

Mine AB 1 1 0 0 2

Mine AC 3 2 3 1 9

Total

70

64

70

53

257

Cable Arcs

Explosion Protection Failures - Mechanical

Area

North East

South East

Total

Incidents

283

407

690

Explosion Protection Failures - Mechanical

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mobile Equipment

201

201

141

120

663

Fire Equipment

15

1

7

4

27

Total

216

202

148

124

690

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mine A 9 2 3 7 12

Mine B 2 0 0 3 5

Mine C 5 12 4 2 23

Mine D 25 16 6 6 53

Mine E 11 8 2 6 27

Mine F 6 1 8 4 19

Mine G 1 0 0 0 1

Mine H 1 0 0 0 1

Mine I 1 2 0 0 3

Mine J 2 2 2 1 7

Mine K 6 2 3 0 11

Mine L 1 4 4 4 13

Mine M 19 21 8 16 64

Mine N 14 23 5 0 42

Mine O 5 5 2 1 13

Mine P 6 3 4 0 10

Explosion Protection Failures - Mechanical

2011 – 12 2012 – 13 2013 – 14 2014 – 15

Total

Mine Q 7 4 4 5 20

Mine R 1 0 1 1 3

Mine S 2 1 4 6 13

Mine T 3 12 6 0 21

Mine U 5 0 3 3 11

Mine V 10 11 3 0 24

Mine W 1 7 2 3 13

Mine X 5 2 10 5 22

Mine Y 1 1 0 0 2

Mine Z 15 6 2 5 28

Mine AA 0 1 13 7 21

Mine AB 13 3 3 6 25

Mine AC 13 23 7 3 48

Mine AD 21 15 8 13 57

Mine AE 3 7 22 11 43

Total

216

202

148

124

690

Explosion Protection Failures - Mechanical

Explosion Protection Failures - Electrical

Area

North East

South East

Total

Incidents

232

363

595

Explosion Protection Failures - Electrical

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Incidents

92

147

173

183

595

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mine A 4 2 9 3 18

Mine B 2 0 0 1 3

Mine C 5 2 3 3 13

Mine D 7 9 16 40 72

Mine E 2 0 4 3 9

Mine F 3 3 3 3 12

Mine G 1 0 0 0 1

Mine H 0 2 0 0 2

Mine I 0 9 8 14 31

Mine J 3 1 7 3 14

Mine K 0 2 0 0 2

Mine L 5 1 2 0 8

Mine M 3 11 11 18 43

Mine N 4 15 10 0 29

Mine O 12 8 8 5 33

Mine P 1 2 0 0 3

Explosion Protection Failures - Electrical

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

Mine Q 2 15 9 12 38

Mine R 4 4 2 3 13

Mine S 0 3 5 7 15

Mine T 0 1 4 1 6

Mine U 1 9 4 2 16

Mine V 3 2 4 1 10

Mine W 1 5 5 11 22

Mine X 7 8 11 4 30

Mine Y 1 0 0 0 1

Mine Z 3 4 8 6 21

Mine AA 1 0 3 16 20

Mine AB 1 7 5 2 15

Mine AC 5 6 11 1 23

Mine AD 4 13 17 16 50

Mine AE 7 3 4 8 22

Total

92

147

173

183

595

Explosion Protection Failures - Electrical

Area

North East

South East

Total

Cable Arcs

168

89

257

Explosion Protection Failures –

Mechanical

283

407

690

Explosion Protection Failures- Electrical

232

363

595

Continued next slide

Area

North East

South East

Total

Conveyor Fires

1

4

5

Drill Rig Gas fire

1

0

1

Coal Self Heating

2

1

3

Total Reported Potential Issues

686

864

1551

Potential Ignition Sources – NOT reported

Strata support bolt failures Conveyor idler bearing failures Conveyor belt rubbing Drill flushing failures Failures detected when equipment is not in

operation

Gas Outbursts – in 4 years

Incidents – Shot firing 23 at mine A – Remote Mining 2 at mine A

Note: a number of shot firing related outbursts involved the ventilation tripping from high methane. The gas outbursts also involved release of significant coal dust.

Gas Trips - Longwall

Area

North East

South East

Total

298

359

657

Gas Trips Total

2011 – 12 2012 – 13 2013 – 14 2014 – 15 Total

285

224

222

179

910

Note: Gas trips not reportable from 1 February 2015 unless > 2.5% CH4. Rarely identified if gas concentration is in explosive range.

What has improved over 4 years?

Compliance with stone dust requirements has improved generally now + 95%.

NOT at a large gassy South Coast mine

Stone dust requirements increase on 1 November 2015

What suggests longwall automation will result in fatalities?

Experience with remote control of LHD’s at metal mines and continuous miners at coal mines

Increase on speed of chock advance Limited walkway Reliance on personnel to constantly move in order to

remain in the ‘safe zone’ Failure to provide proximity detection to ensure personnel

are not in ‘no go zone’ Failure to use proximity detection where provided

Failure to adequately control software by mines and OEM’s

Failure to adequately test and commission the controls after changes made or components changed

Failure to act on OEM safety alerts relating to identified issues

Having too many unknown ‘cooks’ making changes

Lack of competence of supervisors Production pressure

Necessary interaction between personnel and the automated equipment

Failure to adhere to basic principles covering access of personnel into automated operational equipment areas

Failure of electrical controls due to ingress of water

Wear of hydraulic components

The following accidents / incidents have occurred on operational longwalls When sprays were activated shield lowered

because solenoids were swapped

Unplanned Chock Movements Mine No

Mine A 2 Mine B 1

Mine C 3

Mine D 1

Mine E 5

Mine F 2

Mine G 1

Mine H 1

Mine I 1

Mine J 4

Mine K 4

Total 25

Management recommendations

Don’t bog down in everyday issues Identify high risk issues Learn from others Ask questions Identify trends Don’t leave everything to OEM’s Communicate Initiate improvements Monitor change Regularly review your areas