TRANSPORT SAFETY - business- · PDF fileSpecify 2020 objectives for all target ... Long Term •Industry Forums ... •Interaction Risk is a significant contributor to Anglo American

TRANSPORT SAFETY BUSINESS SWEDEN – THE SWEDISH TRADE & INVEST COUNCIL

26 September 2013

UNCLASSIFIED

RP 35 - MANAGING RISK OF

EQUIPMENT – PLANT –

PERSONNEL INTERACTIONS IN

MINING OPERATIONS

Gareth Williams

Head of Safety, Anglo American Plc

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OUTLINE

• Overview of Anglo American

• Challenges in managing transportation risk

• RP 35 Process

• RP 35 Stakeholders

• Interaction Risk Profile

• Reducing Interaction Risks

• Risk Reduction Streams (1..3)

• Current / Planned Systems

• Journey Map

• External Groups

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Our vision is to be the leading global mining company, by being the investment, the partner and the employer of choice by;

• Portfolio of world class assets

• Organising efficiently and effectively

• Operating safely, sustainably and responsibly

• Employing the best people

One of the world’s largest mining companies.

Focused on operating world class assets in the most attractive commodities:

• Iron Ore and Manganese

• Metallurgical coal

• Thermal coal

• Copper

• Nickel

• Platinum

• Diamonds

Over 145,000 permanent employees and contractors

Operations in Africa, Asia, Australia and North and South America

OVERVIEW OF ANGLO AMERICAN

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5

The reality

• High Potential Incident (HPI’s) evidence shows that equipment

collisions are a real risk

• Collision avoidance technology as presently deployed is not

adequately effective

The Group requirement

• Integrated collision avoidance and collision mitigation on

SME’s are required for both present and future fleets

• Collision mitigation : when the collision does occur the

consequences are controlled and reduced

• For haul trucks by eg :

– integrated light/heavy bumpers

– cab location/configuration

– active collision avoidance systems integrated into

operator controls

CHALLENGE ON MANAGING TRANSPORTATION RISK

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RP 35 is the Recommended Practice (RP) for selection and assessment of collision

avoidance systems for the Anglo American Group

NON-COMPETITIVE COLLABORATION

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RP 35 in a nutshell

• Understand and refine the high risk scenarios

• Develop requirements for each scenario

• Analyse gaps in current or new collision

avoidance systems

• Identify and implement improvements with

technology partners

Taking RP 35 to industry

• CRC Mining - Australia

• ISO 17757 and 19014

• RSA – DMR (MOSH)

• Australia – NSW/QLD (MEPIAG)

• OEMs & other mining companies

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FOUR STEPS...

High

• Establish underlying baseline risk for all scenarios using HPI’s and industry registers

Significant

• Identify other controls (such as separation of traffic) and apply these first

Medium

• Assess effectiveness of existing Collision Avoidance System Controls and Treatments

Low

• Analyse gaps in current Collision Avoidance Systems and implement improvements

Risk Level

1

2

3

4

4 Classes of Controls and Treatments (Preventative & Corrective)

5 Types of Collision Avoidance Systems

66 Classifications of Scenario and Site Requirements

330 Categories to define characteristics of Collision Avoidance Systems

RP 35

1 ZTC

2 SAT

3 PAT

4 PDT

5 CAT

Zone Control

Technology for

managing objects

entering, leaving

or within a zone

Safety Adherence

Technology for

managing

behaviour of

objects within a

zone

Collision

Avoidance

Technology to

actively prevent

collisions between

objects

Proximity

Detection

Technology to

automatically

detect the

presence of

nearby objects

Proximity

Awareness

Technology to

assist an operator

to see nearby

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8

RP 35 PROCESS

Understand and refine the High Risk

Scenarios

Identify and implement

improvements with Technology Partners

Develop Requirements for

each Scenario

Analyse Gaps in current or new

Collision Avoidance Systems

Zero Harm

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APPLYING RP 35

WRAC

Process Flows

Process Deviations

Equipment Activities

Baseline / Now

Risk Exposure

Other

Now

New

Requirements

Identify Critical Controls

Assess Control Effectiveness

Measure / Audit Performance

Co

ntr

ols

&

Tre

atm

en

ts

Risk

Reduction

Realised

New

Risk

Exposure

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RP 35 STAKEHOLDER ROLES

Identify interactions with significant risk

Complete interaction risk matrix

Prepare site requirements from RP 35 classifications

Assess capability of now/new technology

Highlight gaps between requirements and capability

Identify critical controls & evaluate effectiveness / measure-audit

Group BU Vendor

A R -

A R -

A R -

I R C

I R C

A R C

Responsible Assists* Consulted Informed

*Modified RACI – clarifies Accountable-Responsible role differences

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INTERACTION RISK PROFILE

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Anglo American Group

Iron Ore - Kumba

Iron Ore - Brazil

Metallurgical Coal

Surface

UG

Copper

Thermal Coal

Surface

UG

Nickel

Platinum

Surface

UG

Niobium

DeBeers

Surface

UG

Phosphate

Business Unit RP 35 Interaction Matrices

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Technology Innovation

Active OTM Community (incl.

OEMs)

Business Unit

Now Technology Selection &

Implementation

OEM Equipment

REDUCING INTERACTION RISK

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Automation

(Stream 3)

Control

(Stream 2)

Assist

(Stream 1)

Operational Risk Management

Machine Interfaces

RP 35 Group

New / Next Technologies

Roadmap Alignment Support

Services

Future Needs Tolerable Risk Profile - Interactions

“2020” Requirements

Business

Unit

13

• Provides assistance to operator of equipment

• Supplements ‘Other’ controls and treatments to manage risk

• Many OTM ‘After Market’ solutions fitted to mobile equipment

• Focus on ‘soft’ Separation controls : Video-Visual-Voice-Audio alarms

• Use of limited signal / data inputs from machine

• Control of machine via human operator only

STREAM 1 - ASSIST

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Heavy reliance on administrative procedures

to manage risk

Challenging to provide two Very Effective

controls to mitigate risks in every scenario

with elevated risk levels

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• OTM ‘After Market’ solutions in development / early stage deployment

• Focus on ‘hard’ Engineering controls to interlock machine

• OEM position on exposing machine controls:

• Underground : Reluctantly working with OTMs

• Surface : Major OEMs are resisting, especially with mobile equipment

• Primary interface to control machine is still via human operator

• Interlocks engage only in specific circumstances

• Reduces risk in specific scenarios

STREAM 2 – CONTROL

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Regulatory environment changing towards

enforcing minimum levels of control as a

mandatory requirement

Careful assessment of risk is crucial in

decision to deploy / not-deploy

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• Major OEMs offering ‘closed’ systems on limited range of equipment

• Aftermarket OTM solutions emerging (mostly without OEM assistance)

• Human operator supervises only (no direct control)

• Risk profile dramatically lowered when full automation is cost effective

• Semi-automation offers reduction in risk for specific cases, e.g.

– Auto-steer on haul road incline / decline (e.g. following pantograph)

– Auto-drill

STREAM 3 - AUTOMATION

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May only be applied to a limited part of the

mobile equipment fleet where the business

case is favorable

OEM closed systems may not be suitable

for many site / operations with mixed fleets

Control interfaces (Stream 2) are critical to

stimulate development of solutions

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INTERACTION RISK REDUCTION

Business Unit (BU) Surface Underground

Business unit 1 -

Business unit 2

Business unit 3

Business unit 4

Business unit 5

Business unit etc

Business unit etc

Business unit etc

Business unit etc

Business unit etc

U

U

N

U

U : Upgrade planned / in progress

N : New system planned / in progress

C : Currently being implemented

D : In Development / Trials

U

D P

D D C

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Phase 1

(to Dec 2013)

Phase 2

(2014-2015)

Phase 3

(2016-2020)

RP 35 Review (across BUs)

• Interaction Matrix

• Gap Analysis

• Control Effectiveness

Define target equipment based on risk

profile and no.s of equipment (group-

wide)

Specific projects aimed at reducing

interaction risks across AA group

RP 35 OEM Engagement

• Operational Risk Profile

• Control Interfaces

• Agree Way Forward

Specify 2020 objectives for all target

equipment – Assist / Control / Automation

Streams

Validation of performance

RP 35 Industry Engagement

• What’s required?

• Who’s interested?

• What participation?

OEM control interfaces defined and

scoped for future equipment purchases

Control interfaces implemented for all

major OEM equipment

RP 35 Support Services in place

across Anglo American Group Update

of RP 35

Initial equipment arriving with control

interfaces in place / initial systems

Risk reduction realised for all new

equipment arriving on-site

JOURNEY MAP

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EXTERNAL GROUPS

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ISO •17757

•19014

•UGM Safety

IEC •61508

AS

SANS

South Africa

•DMR (MOSH)

Australia •NSW/QLD (MEPIAG)

South America

•Chile

•Brazil

•Peru

USA •MSHA

Long Term •Industry Forums

•Leader Groups

•Peak Bodies

Medium Term

•OEM Engagement

•Targeted Projects

Lead / Influence

•Conferences

•Expos

Industry

Standards

Regulatory

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• Project Coordination

• Industry Group Representation

– CEO level

– Delegate level (e.g. Engineering Council)

– Expert/practitioner level

• M&T Engineering

– Group Technical Standards

(incl. update of RP 35)

– ISO / IEC Standards Development

– OEM Engagement

RESOURCES

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• S&SD Operational Risk Management – Risk &

Assurance

• M&T Technology Development – Automation

Streams

• RP 35 BU/Site Support

• RP 35 Training

Under direction of Transportation Safety Risk Improvement Group:

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• Interaction Risk is a significant contributor to Anglo American risk exposure

• We are using RP 35 to identify key risk areas and to implement suitable controls for now and future in

a ‘risk driven approach’

• Ultimate objective is for equipment to suitably equipped when it arrives on Anglo American sites

• Expect that more standard types of Collision Management System controls will become standard on

most OEM equipment (e.g. camera, radar where applicable) with simple interfaces initially

• Industry engagement is critical and we are seeking the right support that will foster development of

standards

CONCLUDING REMARKS

SECURITY CLASSIFICATION

THANK YOU

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