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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Ex equipment in NSW Coal MinesEx equipment in NSW Coal Mines--
An Australian (NSW) regulators An Australian (NSW) regulators perspectiveperspective
John Francis WaudbySenior Inspector of Electrical EngineeringMine Safety Operations
IEC Ex Meeting – Shanghai, P.R. China – Sept 2006
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Overview of this presentationINTRODUCTION
Mining in NSWMine Safety Operations – Electrical Engineering Safety
Ex EQUIPMENT IN COAL MINESTypes of equipmentHistorical approachDamage to Ex equipment
THE REGULATOR AND IEC ExPrinciples for life cycle mangement of Ex equipmentIEC Ex supporting the regulator
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
CoalMetalliferousQuarryingSand DredgingOpals
Fatality rate = 1/yearLTIFR = 16 per million hoursLast fatality 26/07/2006Previous fatality 14/06/2005
Mining in NSWMining in NSW
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Coal Mining in NSWCoal Mining in NSWNumber of O/C mines = 38
Number of U/G mines = 37
$6 billion of coal exports
$400 million in royalties to the state government
Total production = 150,000,000 tonnes / annum
Total U/G production = 50,000,000 tonnes / annum
Total employment = 12,000
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Electrical Engineering SafetyElectrical Engineering Safety--
NSW Mining Regulators NSW Mining Regulators ApproachApproach
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
MINE SAFETY OPERATIONS: Engineering Approach
Ω System safety engineeringΩ Hierarchy of risk controlsΩ Hazard reduction precedenceΩ Risk controls are best
implemented at the design stage
Ω Provision of life cycle information
Ω Life cycle management
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Electrical Engineering Safety (EES)Electrical Engineering Safety (EES)
Vision:
A mining industry that has eliminated death and injuries from
electrically powered and electrically controlled equipment.
Ω Prevention of gas and/or dust explosions,
Ω Prevention of electric shock and burns,
Ω Prevention of fires,
Ω Prevention of unintended operation of equipment,
Ω Provision of electrical safeguards.
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Coal Mining Coal Mining -- EES PerformanceEES Performance
Ω Last fatal accident 22 years ago
Ω Last electrocution 23 years ago
Ω Last fatal explosion 27 years ago
Ω Explosions / major gas ignitionsΩ 8/1/1979 - West WallsendΩ 24/7/1979 – AppinΩ 28/6/1995 - EndeavourΩ 12/12/1997 - Munmorah
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Ex Equipment in Underground Ex Equipment in Underground Coal MinesCoal Mines
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
415V Control station 415V Control station –– courtesy Ampcontrolcourtesy Ampcontrol
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall lighting and control Longwall lighting and control –– Courtesy DBTCourtesy DBT
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall chock control Longwall chock control –– Courtesy DBTCourtesy DBT
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall Shearer Longwall Shearer –– Courtesy Joy Courtesy Joy ManufacturingManufacturing
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall sub station Longwall sub station –– Courtesy AmpcontrolCourtesy Ampcontrol
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Longwall sub station Longwall sub station –– Courtesy AmpcontrolCourtesy Ampcontrol
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Transformer subTransformer sub--stationstation
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Bolter Miner Bolter Miner –– CoutesyCoutesy VoestVoest AlpineAlpine
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Bolter Miner Bolter Miner –– Courtesy Courtesy AustarAustar
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Roof bolting Roof bolting –– Courtesy Courtesy AustarAustar
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
RoadheaderRoadheader –– Courtesy Courtesy VoestVoest AlpineAlpine
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Continuous Miner Continuous Miner –– Courtesy Joy ManufacturingCourtesy Joy Manufacturing
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Continuous Miner Continuous Miner –– Courtesy MSHACourtesy MSHA
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Continuous Miner Continuous Miner –– Courtesy MSHACourtesy MSHA
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Miner loading a shuttlecar Miner loading a shuttlecar –– Courtesy Joy Courtesy Joy ManufacturingManufacturing
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Miner loading a shuttlecarMiner loading a shuttlecar–– Courtesy Courtesy AustarAustar
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
ShuttlecarShuttlecar
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Aux Fan Aux Fan –– Courtesy Courtesy AustarAustar
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
NSW Mining RegulatorsNSW Mining RegulatorsExperience with Ex EquipmentExperience with Ex Equipment
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
A short history of dealing with Ex equipment A short history of dealing with Ex equipment ––Equipment approvalEquipment approvalΩ From the early 1970’s Ex equipment was approved by the CICM
Ω Based on a test report
Ω Reviewed by a competent engineer
Ω Approval documents and approval number issued – no time limit
Ω Database of approvals kept
Ω Some approvals were issued with non - compliance to standards
Ω Approval was initially free
Ω Conditions of manufacture / use were specified
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– Ex repair and mine managementEx repair and mine management
Ω From the late 1970’s:Ω Ex repair workshops were approved
Ω Ex equipment workers - examined by the regulator
Ω Mine electrical engineers examined by the regulator
Ω Approval / competency schemes were credible
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– From approval to certificationFrom approval to certification
Ω Approval and competency schemes evolved
Ω Legislation embraced contemporary OH&S Management
Ω National certification schemes matured
Ω This changing mix + industry culture allowed changes to approval
Ω At this point in time the IEC Ex scheme commenced
Ω An interim step of accepting IEC Ex CoC’s from Australian CB’s
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– Hazardous area incidentsHazardous area incidents
Ω Evidence of arcing on U/G mining cables
Ω Failure of Ex properties of equipment
Ω We keep cable damage statistics
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
0
10
20
30
40
50
60
99 / 00 00 / 01 01 / 02 02 / 03 03 / 04 04 / 05
TOTAL
Enclosure – switchgear,JB, switchMotor – Including JB
Gland / Receptacle /PlugLight
Window
In Service Failure of Ex ApparatusIn Service Failure of Ex Apparatus
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
A Regulators ExpectationsA Regulators Expectations&&
IEC Ex SchemesIEC Ex Schemes
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Summary of a regulators point of view on Summary of a regulators point of view on Ex equipmentEx equipmentΩ Coal mine explosions are high risk events.
Ω Ex is a critical risk controlΩ Additional scrutiny is needed.
Ω The scrutiny must be credible
Ω Ex equipment must be Ex throughout its life.Ω When new, it is as good as it gets
Ω Ex supported by the correct regulatory requirements
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Principles for managing Ex equipment Principles for managing Ex equipment --Additional scrutinyAdditional scrutinyΩ The additional scrutiny must:
Ω be applied at the proper points of the equipment life cycle.
Ω support all activities throughout the life cycle.
Ω support the hierarchy of risk controls
Ω support the hazard reduction precedence
Ω provide for a level of risk less than or equal to what we do now
Ω recognise the harsh mining environment
Ω be competent
Ω be credible
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Principles for managing Ex equipment Principles for managing Ex equipment --Credible scrutinyCredible scrutinyΩ set standard
Ω consistent and repeatable
Ω competent people
Ω proper procedures
Ω fit for purpose equipment & facilities
Ω managed work environment suitable for detailed technical evaluation
Ω work environment where cost does not overly influence the testing approach, reporting and review.
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Principles for managing Ex equipment Principles for managing Ex equipment --Current & proposed NSW legislationCurrent & proposed NSW legislationΩ Legislation requires
Ω Application of the hierarchy of risk controls
Ω Ex equipment to be certified
Ω Suppliers of equipment to provide sufficient life-cycle information
Ω Requires mines to have Ex repairs done at licensed facilitiesΩ Licensed facilities to have competent people
Ω Requires mines to have a mine electrical engineer
Ω Requires mines to have an Electrical Engineering Management Plan
Ω Requires mines to establish electrical competency requirements
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?
Ω Incorrect design of Ex = explosions in minesΩ Standards of design
Ω Competent designers
Ω Third party design verification
Ω Confidence in the manufacture
Ω Ex equipment arrives at the mine in an Ex condition.
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?
Ω Ex equipment arrives at the mine in an Ex condition.
Ω Equipment is installed, commissioned, maintained & used properlyΩ Provision of information
Ω Independent assessment at design verification stage
Ω Selection, installation, commission, inspect and maintenance standards
Ω Competency for management of Ex
Ω Competency for install, commission, inspect, maintain and operate
Ω Independent assessment of competency
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?
Ω Ex equipment has a hard life at the mine
Ω Ex management dictates overhaul and repair
Ω Equipment overhauled and repaired back to its certified stateΩ Provision of information
Ω Repair and overhaul standards
Ω Independent assessment of competencies
Ω Independent assessment of workshops Ω Facilities, tools, equipment and measurement
Ω Work processes, competencies and management systems
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Summary Summary -- IEC Ex supporting the regulatorIEC Ex supporting the regulator
Ω The IEC Ex standards and IEC Ex schemes provide for:Ω hierarchy of risk controls
Ω hazard reduction precedence
Ω provision of information
Ω each element of the Nertney Wheel
Ω life cycle management
Ω appropriate independent assessment at appropriate points
Ω All of the above is required by contemporary OH&S legislation
Ω All of the above supports the aims of the Australian, NSW regulator
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
IEC Ex supporting the regulator IEC Ex supporting the regulator –– the the current situationcurrent situation
Ω Currently the DPI:Ω is considering full acceptance of the IEC Ex scheme.
Ω has proposed full acceptance & canvassed industry comment
Ω Industry’s wishes will be implemented via a notice
Ω A decision will be made in 2006 or early 2007
Ω The regulator still retains prohibition powers
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
CONCLUSIONSCONCLUSIONSΩ The IEC Ex standards and schemes can aid:
Ω Life cycle management of Ex equipment
Ω The regulator’s aims for electrical engineering safety
Ω A mine operator’s fulfilment of OH&S obligations
Ω An equipment suppliers fulfilment of OH&S obligations
Ω Credibility of the schemes is a critical component
Ω We have our point of view and respect others
Ω We are committed to a highly credible IEC Ex scheme
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NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS
Contact detailsContact details
Website: www.minerals.nsw.gov.au/safety
Email: [email protected]