SACEA TMM/PDS SAFETY WORKSHOP WS 2015 TMM RegProm... · EXXARO - Grootegeluk Coal Mine (0252) MHSA...
Click here to load reader
Transcript of SACEA TMM/PDS SAFETY WORKSHOP WS 2015 TMM RegProm... · EXXARO - Grootegeluk Coal Mine (0252) MHSA...
EXXARO - Grootegeluk Coal Mine (0252) MHSA TMM Regulations Promulgated 27 February 2015
Compliance Review
SACEA TMM/PDS SAFETY WORKSHOP
11 June 2015
CONTENT 1
SHE Committee Members
Vision and Purpose
Background
Amended MHSA Regulation Review
Summary and Closure
SHE Committee 2
NAME OF ATTENDEES REPRESENTATION DESIGNATION Att.
Employer Representative
Johan Wepener Employer Representative General Manager – Section 2(A)
Rico van Staden Mining Operations Operations Manager Mining – Sec 3(1)A P
Adrie Conradie Beneficiation Operations Operations Manager Beneficiation – Sec 3(1)A P
Health and Safety Representatives
Sipho Khumalo Employee Representative (GG) FT SHEQ Rep Eng. (Central) – Section 6(9) P
Hendrik Matlou Employee Representative (GG) FT SHEQ Rep Eng. (Plant)– Section 6(9)
Glorius Mabelane Employee Representative (GG) FT SHEQ Rep Eng. (Mining)– Section 6(9) P
Kwena Pitjeng Employee Representative (GG) FT SHEQ Rep Mining– Section 6(9)
Builoe Seleka Employee Representative (GG) FT SHEQ Rep Plant– Section 6(9)
Trade Unions
Robert Madonsela NUM Representative Fulltime Shop Steward
Hazel Pole NUM Representative Fulltime Shop Steward P
Amon Malaudzi NUM Representative Shop Steward
Jan Pretorius Solidarity Representative Fulltime Shop Steward
Herman Kriel Solidarity Representative Shop Steward P
SHE Committee 3
NAME OF ATTENDEES REPRESENTATION DESIGNATION Attendance
Management Representation
Caesar Nokwe Mining Operations Manager Mining – Reg. 2.6.1 P
Baltimore Miles Mining Operations Eng. Manager – Reg. 2.13.1 P
Tjaart v/d Walt Mining Operations Head SHE – Reg 2.17.4
Adam Wieruszowski Beneficiation Operations Manager Beneficiation – Reg 2.6.1
Job Sithole Beneficiation Operations Eng. Manager – Reg. 2.13.1
Susan Pheiffer Beneficiation Operations Head SHE – Reg. 2.17.4 P
Stompie Nel Central Engineering Eng. Manager – Reg. 2.13.1 P
Derrick van Zyl Central Engineering Head SHE – Reg. 2.17.4
Hasie Haasbroek SHEC SHEC Manager – Reg. 2.6.1
Wayne Mulligan SHEC Head Safety – SHEC P
Marietjie Hale Mining Operations Assistant Eng. Manager – Reg. 2.13.3.1
Tamara Qwatekana Mining Operations Pit Supt. – Reg. 2.6.1
Dominic Mpati Plant Operation Assistant Eng. Manager – Reg. 2.13.3.1
Ronnie Mvelase Plant Operation Pit Supt. – Reg. 2.6.1
SHE Committee 4
NAME OF ATTENDEES REPRESENTATION DESIGNATION Attendance
New TMM License Implementation
Willem Hoffman Human Resources Manager, HR Development P
Jacqueline Khalo Human Resources Training
PDS Implementation
François van Niekerk Exxaro Mobile Technology EXXARO PDS Champion P
Johann Kruger Exxaro HQ Projects Project Manager
Vicente Alvarado Engineering Development Manager, Engineering Development
Henry Lefawane Engineering Development Project Engineer P
Madele Nelson Human Resources PDS Adoption Change Manager
TMM COP Update
Marietjie Hale Mining Operations Assistant Eng.. Manager – Reg 2.13.3.1
Purpose of this Presentation
Primary Purpose is to address the risk associated with TMM / TMM / Pedestrian collisions in order to support Exxaro’s ZERO HARM Intent
Secondary purpose is to comply with the amendment to the MHSA regulations regarding TMMs promulgated on the 27 February 2015
5
Vision Through our innovation and growth we will be a powerful source of endless possibilities by producing 40 million safe tonnes of product
by 2020
Background
MINING METHODS Conventional opencast truck and shovel operation.
The pit is ±120 meters deep
Some 68 million tons of material is transported out of the pit.
Some 40 million tons is fed to 8 beneficiation plants
DESCRIPTION OF TMM’s (~1187) ~ 145 TMMs used for primary mining activates
~ 445 Service and Maintenance TMMs
~ 74 Contractor TMMs
~ 104 Coal link Trucks
~ 419 Employee Private Vehicles (V-Permits)
6
Background
Safety Performance
7
2010 2011 2012 2013 2014Collision 13 29 23 39 39Fatigue 2 2 2 6 1Damages 13 27 25 43 39Minor 1 3 2 1 3LTI 0 1 2 0 0Fatality 0 0 1 0 0
05
101520253035404550
Num
ber o
f inc
iden
ts
5 year historical data of TMM incident classification in mining
Background
1. Section 11 Employer’s Responsibility
1. Employer to assess and respond to risk
2. Employer must, after consulting the H&S committee, determine measures to: a) Eliminate any recorded risk b) Control the risk at source c) Minimise the risk d) In so far as the risk remains:
i. Provide for PPE ii. Institute a Program to monitor the risk to which employees are exposed to
8
Level of Risk Mitigation Administrative Control Probability of Fatal Engineering Control Probability of FatalEliminate Maintenance and Operations Time Shared Unlikely Autonomous/remote operations RareControl Following Distances, safe parking, Lock-out of areas Possible Segregated traffic Plan UnlikelyMinimise Proximity Detection Systems, blind Spot Camera's Likely Collision Avoidance System PossiblePPE Almost Certain Haul Truck Bumpers Likely None Almost Certain Almost Certain
Presentation Philosophy and Content 9
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier (Onsite Trials)
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit Summary : Amended MHSA Chapter 8 Regulation
10
TMM Regulations Yard Sticks ASPECTSTO BE ADDESSED IN THE MANDATORY TMM COP ComplianceCollisions between trackless mobile machines and pedestrians Pedestrian Detection (PD) System YCollisions between diesel powered trackless mobile machines Anti Collision Devices NCollisions between trackless mobile machines and rail bound equipment Anti Collision Devices YTrackless mobile machines running uncontrolled 8.4 Inadvertent movement of the TMM YOverturning of any trackless mobile machine Roll-Over Protection Systems (ROPS) 8.3 Protection of driver/operator or other persons YObjects falling onto operators and/or passengers of trackless mobile machines Falling Objects Protection Systems (FOPS) 8.3 Protection of driver/operator or other persons YPersons inadvertently falling out of or being ejected from trackless mobile machines. Brake Interlocking (Doors) 8.3 Protection of driver/operator or other persons YBraking systems Brake Test Ramp 8.2 Brakes YRestricted operator visibility. 8.8 Physical constraints to operator’s/driver’s vision. YFatigue while operating a trackless mobile machine. Fatigue Management YBattery charging facilities 8.10.9 Batteries control and safety NDiesel refuelling facilities YWheels, tyres and rims 8.10.4 Procedures for changing wheels, 8.10.5 Changing, Inflating and repairing tyres YAccess of persons to and from the trackless mobile machines 8.5 Safe boarding/alighting and/or access to/exit from TMMs YVisibility of trackless mobile machines, skid mounted machinery and trailers to persons. 8.18 Visibility ofTMMs and persons YUnauthorised access to or operation of trackless mobile machines. 8.12.6 Key control YIsolation and lock-out of trackless mobile machines 8.10.6 Procedures for any repairs that could endanger persons YOperating procedures 8.15 Operating rules YMaintenance standards and procedures Maintenance Systems 8.10 Maintenance YRemote and remotely controlled trackless mobile machines 8.9 Remote controlled TMMs N
Trailers8.6.2 Procedure for coupling, The methods and procedures to prevent inadvertent de-coupling of TMMsbeing towed or pushed. Y
Towing and recovery of trackless mobile machines 8.6 Design and operation of tow-bars and coupling devices YRoadway conditions 8.13 Design of excavations and road ways YSelection, training, appointment and licensing of trackless mobile machine operators Fitness to Perform Work (Medical) 8.12 TMMs to be operated/driven by competent, authorised persons NPre-use inspection procedures Pre-Use Checklists 8.10.2 Pre-use checklists NReversing over the edge of a stockpile 8.15 Operating rules YInadvertent movement of the trackless mobile machine 8.4 Inadvertent movement of the TMM YMandatory carrying of license 8.12 TMMs to be operated/driven by competent, authorised persons YCertain regulations not applicable Y
Illumination 8.17 Illumination of transport environmentContractors' PacksProcurementFire ExtinguishersFire SuppressionsEmergency PreparednessErgonomics AssessmentEquipment Noise MonitoringChecklist of all TMMs 8.10.2 Pre-use checklists
8.1 Safe use ofTMMs, equipment and tools Compliance 24 8.7 Lights fitted to TMMs
Non-Compliance 5 8.14 Inclined applications8.16 Raising/lowering, suspension and transport of persons
% Compliance 83% 8.19 Warning devices and signals8.20 Personal protective clothing
Audit : Amended MHSA Chapter 8 Regulation 11
Regulation Compliance Findings Actions DateCollisions between trackless mobile machines and pedestrians
Y Only applicable to underground Mines
Collisions between diesel powered trackless mobile machines
N GG Red Area has a significant Risk hence PDS is required
Implement PDS on all TMMs operating in the red permit area
09-Sep-16
Collisions between trackless mobile machines and rail bound equipment
Y
Although only applicable to underground; Access to rail bound equipment(RBE) in the plant area is restricted and a policy exists for TMM interaction. (Backfill spreader will be addressed as part of PDS roll out)
Trackless mobile machines running uncontrolled Y
TMM COP 8.2, 8.4.2, 8.10 & 8.15. Brakes are selected, maintenance and tested before use to prevent brake failures. Parking procedures on inclines/declines of which certain TMMs incorporate stop blocks. Steering's systems are maintenance to prevent failures. Operators are trained on safe operation of TMMs and emergency procedures. In open pit arrestor berms are provided on permanent haul roads
Audit : Amended MHSA Chapter 8 Regulation 12
Regulation Compliance Findings Actions Date
Overturning of any trackless mobile machine Y
TMM COP 8.13, 8.14, & 8.15. TMM road ways are designed to prevent TMMs overturning. E.g. gradient < TMM safe gradient. Safety devices are provided for safe operation on inclines/declines. Operator are trained in the safe operation of TMMs. All Pit TMMs except LDV's are fitted with ROPS
Objects falling onto operators and/or passengers of trackless mobile machines Y
TMM Following distance of 50m and stand-off Distances to high walls to prevent objects from falling onto TMM operators/passengers. All Pit TMMs except LDV's are fitted with FOPS
Persons inadvertently falling out of or being ejected from trackless mobile machines. Y
No persons in load box of LDV, persons only seated in seats with seatbelts. All Cabs enclosed except skid steer loader
Braking systems Y
TMM COP 8.2 & 8.10. All TMMs are fitted with combined fail safe braking systems as per mines Risk assessment. Refer to TMM COP Annexure A. Service brakes are maintained to 19%*g for a fully loaded TMM. Off the road TMMs brakes comply to ISO 3450 specifications and on the road TMMs brakes comply with National Road Traffic Act roadworthiness requirements. All operators are required to check the operations of brakes as part of TMMs pre-use. TMMs entering the open pit incorporate a brake test ramp as part of the pre-use
Audit : Data : Braking Systems 13
8.10.7 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of brake failure. Such measures must include ensuring: Regulation Off the Road TMM On the Road TMM
8.10.7.1 that trackless mobile machines are operated with adequate and effective braking systems;
ISO 3450 Specification National Road Traffic Act, Compliance Specification
8.10.7.2 all braking systems are adequately and routinely tested for intended functionality;
Pre-use Check using Brake Test Ramp
Pre-use Check using Level Road &/or Brake Test Ramp
8.10.7.3 all braking systems are regularly maintained; and
500 hr. Service & Simret Test
Service Interval brake inspection and service
8.10.7.4 that where a combined braking system is used, the design of the braking system is such that it complies with the requirements for the separate systems and that it fails to safe.
ISO 3450 On site Verification
Local Municipality Road Worthy certificate
Audit : Data : Braking Systems : ISO 3450 Verification
14
Verification test procedure:
Do Simret brake test, ensure brake efficiency is better than 29% x gravity Load truck as close as possible to 120% payload Go over brake test ramp and verify brakes Brake test:
Drive truck down slope of 8% Accelerate to speed of approximately 50km/h Apply service brakes at pre – determined point Mark and measure stopping distance Truck should comply to ISO3450 standard
Repeat above and stop using service and park brakes for references purposes History – All EH3500 ACII – Failed On site verification Hitachi & GG upgraded brake pads Adjusted brake pressures and re-did tests All trucks now comply
Presentation Philosophy and Content 15
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier (Onsite Trials)
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Amended MHSA Chapter 8 Regulation 16
Regulation Compliance Findings Actions Date
Restricted operator visibility. Y
TMM COP 8.8. Most TMMs have visibility charts. These charts have been incorporated into operator training. GG induction illustrates this restriction to make pedestrians and other TMM operators ware of this restriction. Haul Trucks are the highest risk with regard to restricted vision and have thus been fitted with camera systems to augment visibility
Update TMM COP with outstanding visibility charts of remaining TMM and contractor TMMs
31-Aug-15
Fatigue while operating a trackless mobile machine. Y
Procedure (GG OPI B01-031 REPORTING IN CASE OF SICKNESS, TIREDNESS AND SLEEPINESS) to manage fatigue but relies on operator feedback
Investigate Safe mine Fatigue Monitoring system 15-Dec-15
Battery charging facilities N
Pit TMM Battery charging facility complies but ventilation can be improved. SCM and Pool Workshop Battery charging Facility does does not have an effective provisions to treat persons in the event of acid spillage; Pool WS does not have adequate Lighting. SCM does not have adequate ventilation
Implement an effective provisions to treat persons in the event of acid spillage and a ventilation scheme to comply with 0,5m/s and adequate lighting
31-Aug-15
Diesel refuelling facilities Y
Total diesel and lubricant Facility is an open air installation fitted with fire fighting equipment and designed to comply with SANS 10089-1,2,3.
Audit : Data : Restricted operator visibility 17
EH3500 Haul Truck Visibility Chart
EH3500 Haul Truck Visibility Chart with Camera Assist
8.10.8 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of restricted operator visibility.
Audit : Data : Fatigue while operating a trackless mobile machine
18
8.10.9 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of fatigue of operators. GG OPI B01-031 REPORTING IN CASE OF SICKNESS, TIREDNESS AND SLEEPINESS The above procedure encourage TMM operators to book tired is they feel they are unable to operate safely. The procedure allows for a rest period to combat fatigue. SAFEMINE FATIGUE MONITORING to be investigated as part of PDS Roll Out
Online Fatigue Monitoring Investigation 19
Integrate with SM CAS technology: Driving performance: harsh braking,
swerving, cornering
Interaction with vehicles: alarms, reaction time, dangerous behavior
Measure development over time, driver specific
Audit : Data : Pit TMM Battery charging facilities 20
8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through
ventilation; ii) Adequate fire
suppression equipment; iii) Effective provisions to
treat persons in the event of acid spillage; and
iv) Appropriate and adequate lighting.
0 – 3.9m/s vs 0.5m/s
192 lux vs 100 lux
Audit : Data : SCM Battery charging facilities 21
8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through
ventilation; ii) Adequate fire
suppression equipment; iii) Effective provisions to
treat persons in the event of acid spillage; and
iv) Appropriate and adequate lighting.
0m/s vs 0.5m/s
498 lux vs 100lux
No effective provisions to treat persons in the event of acid spillage. No eye wash or emergency shower
Audit : Data : Pool Workshop Battery charging facilities
22
8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through
ventilation; ii) Adequate fire
suppression equipment; iii) Effective provisions to
treat persons in the event of acid spillage; and
iv) Appropriate and adequate lighting.
No effective provisions to treat persons in the event of acid spillage. No eye wash or emergency shower
3,7 ; 3,4 vs 0.5m/s
104 lux vs 100 lux
26 lux vs 100 lux
Audit : Summary : Battery charging facilities 23
Recommendations Implement an effective
provisions to treat persons in the event of acid spillage and a ventilation scheme to
comply with 0,5m/s and adequate lighting
Action Responsible Due date Comment CompletionDesign, procure and construct an effective provisions to treat
persons in the event of acid spil lage at SCM & Pool
Workshop
Heinrich Bornman 31-Aug-15 0%
Design, procure and construct a ventilation scheme to comply to
0,5m/s in SCMHeinrich Bornman 31-Aug-15 0%
Install additional l ighting in Pool W/S
Heinrich Bornman 31-Jul-15 0%
Install additional vent in Pit Facil ity
Heinrich Bornman 31-Jul-15 0%
Regulation Audit Finding8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facil ities are
ergonomically designed, constructed and equipped with the following: i) Adequate through ventilation; i i) Adequate fire
suppression equipment; i i i) Effective provisions to treat persons in the event of acid spil lage; and iv) Appropriate and adequate
l ighting.
Pit TMM Battery charging facil ity complies but ventilation can be improved. SCM and Pool Workshop Battery charging Facil ity
does does not have an effective provisions to treat persons in the event of acid spil lage; Pool WS does not have adequate
Lighting. SCM does not have adequate ventilation
Action Plan
Audit : Data : Diesel refuelling facilities 24
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through ventilation;
Open Air Surface Facility ii) Adequate fire suppression equipment;
Audit : Data : Diesel refuelling facilities 25
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: iii) Effective provisions to cater for oil and diesel spillages; and
Audit : Data : Diesel refuelling facilities 26
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: iv) Appropriate and adequate lighting.
Audit : Data : Diesel refuelling facilities 27
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with:
a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulk installations.
Spill Slab and Fall Protection Units are designed according to SANS 10089-1 (2008)
Audit : Data : Diesel refuelling facilities 28
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with: b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector.
Audit : Data : Diesel refuelling facilities 29
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with: c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.
Audit : Data : Diesel refuelling facilities 30
8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: i. Adequate through ventilation; Comply ii) Adequate fire suppression equipment; Comply iii) Effective provisions to cater for oil and diesel spillages; and Comply iv) Appropriate and adequate lighting. Comply v) Surface diesel refueling facilities are in accordance with: Comply a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulk installations. b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector. c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.
Presentation Philosophy and Content 31
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Amended MHSA Chapter 8 Regulation 32
Regulation Compliance Findings Actions Date
Wheels, tyres and rims Y
TMM COP 8.10.4 & 8.10.5 Procedures for changing wheels, Changes and maintenance of tyres on equipment and the associated risks are addressed in BPI GG/I01.078 BPI and GG/I02.056
Access of persons to and from the trackless mobile machines
Y
TMM COP 8.5.1 All TMMs are provided with safe access facilities to theoperator’s cabin. All relevant personnel are trained regarding the associateddangers and correct procedures to follow regarding boarding onto, alightingfrom, riding on or working on top of TMM’s.
Visibility of trackless mobile machines, skid mounted machinery and trailers to persons. Y
TMM COP 8.10.2. & 8.18. All TMMs have reflective strips, reverse hooters and directional hooters where applicable and rotating strobe lights which also form part of the TMMs pre-use checklist
Unauthorised access to or operation of trackless mobile machines. Y
TMM COP 8.12.6 Key control procedure (GG/SPI/J00.100), proxy system on primary GG owned TMMs is implemented to prevent unauthorized access or operation
Audit : Data : Access of persons to and from the trackless mobile machines
33
Audit : Data : Visibility of trackless mobile machines, skid mounted machinery and trailers to persons.
34
Presentation Philosophy and Content 35
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Amended MHSA Chapter 8 Regulation 36
Regulation Compliance Findings Actions Date
Isolation and lock-out of trackless mobile machines Y
TMM COP 8.10.6 All primary TMM have specific lockout procedures and isolations points on TMMs, Haul Trucks and Shovels have IRB (Isolation Record Book). Procedures BPI/I01.075, BPI/I01.076 and BPI/01.077 are examples of machine specific lock out procedures
Operating procedures Y
TMM COP 8.15 details operating procedures. SPI GG/B00.004, BPI/B01.001, BPI/B01.007,BPI/B01.009,etc..
Maintenance standards and procedures Y
TMM COP 8.10. Maintenance of all machines is scheduled in accordance with maintenance schedules as per the OEM’s manuals and guidelines. Maintenance Schedules are registered in the SAP system as per BPI.I04.032. Regular inspections are carried out by persons appointed by the AME and to assist him in enforcing the regulations andsafe working procedures.
Remote and remotely controlled trackless mobile machines
NGG uses an MMD Atlas Transporter to move IPCC and Backfill systems which is a RC TMM. No SANS 61000 certification
Engage MMD (OEM) to get transporter certified
31-Aug-15
Audit : Data : Isolation and lock-out of trackless mobile machines : TMM Specific Lock Out Code
37
Identify TMM Type / group
Identify all Energy Sources
Apply isolation and lockout
guideline A to H
Identify Tasks that require lock-out of
TMM
Develop Task vs Lockout
Matrix
Procedure Decription
BPI GG I01.077 Isolation and Swithching procedure for Mechanical and Electrical Equipment at Auxilliary Equipment Rev.1
OPI GG I01 075 GENERAL ISOLATION AND SWITCH - ON PROCEDURE FOR MINING MAINTENANCE SHOVELS AND POWER DISTRIBUTION REV 4
OPI GG I01.076 GENERAL ISOLATION AND SWITCHING ON FOR PRIMARY TRUCKS REV 3
Audit : Data : Operating procedures 38
OPI GG B02 001 DRILLING Rev3 OPI GG B01.045 HYDRAULIC SHOVELS REV.1
OPI GG B01 049 Stripping of top soil Rev 1 OPI GG B01 048 - Operating a cable reel machine REV1
OPI GG B01 032 HANDLING OF DEFECTIVE MINING EQUIPMENT REV3 OPI GG B01 001 PH SHOVELS AND LOADING REV6
GG OPI B01.050 OPERATION OF LOWBED REV1 GG OPI B01.044 RUBBERWHEEL DOZER REV1 docx
GG OPI B01.043 HAUL TRUCK CAT 777 GG OPI B01.006 Operation of Water truck
GG OPI B01 018 Waste Rock Dumps Revision 7 GG OPI B01 002 OPERATING OF HAUL TRUCKS Rev9
BPI GG BPI B01.003 Graders BPI GG B01.047 OPERATING A BACK ACTOR REV2
BPI GG B01.004 TRACK DOZERS BPI GG B01 053 FRONT END LOADER_992, 928 966_ REV 1
BPI GG B01 051 Operation of RUBBERWHEEL DOZER 824 at shovels Rev 1 BPI GG B01 046- OPERATING A ROAD COMPACTOR REV1
BPI GG B01 028 FRONT END LOADER _994_ Rev 3
Audit : Data : Remote and remotely controlled trackless mobile
39
8.10.19 The employer must take reasonably practicable measures to ensure that remote control devices for trackless mobile machines using a wireless remote control device comply a) SANS 61000-4-2 (IEC 61000-4-2) b) SANS 61000-4-3 (IEC 61000-4-3) c) SANS
61000-4-4 (IEC 61000-4-4) d) SANS 61000-4-5 (IEC 61000-4-5) e) SANS 61000-4-6 (IEC 61000-4-6) f) SANS 61000-4-8 (IEC 61000-4-8) g) SANS 61000-4-11 (IEC 61000-4-11)
b)No Certification however crawler remote is designed to SANS 61000-4-3. Crawler relies on
remote control serial number encryption
Presentation Philosophy and Content 40
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Amended MHSA Chapter 8 Regulation 41
Regulation Compliance Findings Actions Date
Trailers Y
No Trailers are manufactured on site. Trailers are specified and purchased from various OEMs. 8.6.2 Procedure for coupling / decoupling.
Towing and recovery of trackless mobile machines Y SPI GG/J02.008 stipulates procedure for towing.
Roadway conditions Y
SPI/GG/B00.004 7.4, 7.5 & 7.6 stipulates road design parameters. The width of haul roads is stipulated at a minimum of 2.5xMaximum width of TMM. Road demarcations and barricades are also stipulated. Daily inspection are conducted on Bench roads and weekly site servility surveys on permanent roads. Plant roads are also maintained and tarred roads are resurfaced every 7 years and refurbished every 20 to 25 years.
Selection, training, appointment and licensing of trackless mobile machine operators N
Operators of trackless mobile machines are not authorized in writing by their supervisor. Current License do not display operators photograph and the issue date of the license
Update TMM operator authorization procedure in line with MHSA regulation 8.10.23
30-Nov-15
Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators
42
Selection, training, appointment and licensing of trackless mobile machine operators
Finding Compliance Action Date
8.10.23.1 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the selection, training, appointment and licensing of trackless mobile machine operators, which procedures must include:
8.10.23.1 physical and psychological pre-selection criteria;Physical Ability Assessment (PAA) is conducted as part of selection criteria. Dover Testing is done as part of psycholigal criteria.
Y
8.10.23.2 a training programme for trackless mobile machine operators, covering:
i) theoretical training in a training Centre;Each TMM has a training manual linked to the operating procedure of the TMM
Y
ii) practical training; andEach TMM has a practical training component inked to the operating procedure of the TMM and assessed by way of a PTO
Y
iii) on the job training.Each TMM has on the job training which is assessed by a training instructor
Y
8.10.23.3 assessment of the trainee, on successful completion of the training programme, by a competent person;
GG/OPI/B01.017 7.2 stipulates what the competency declaration must include and who must conduct it
Y
8.10.23.4 that only operators, assessed to be competent are authorised in writing by the responsible engineer to operate trackless mobile machines;
GG/OPI/B01.017 7.3 stipulates authorization by the AME (Responsible engineer)
Y
8.10.23.5 that operators of trackless mobile machines are authorized in writing by their supervisor to operate trackless mobile machines. Such authorization must detail their duties, responsibilities, limitations and areas of operation.
NUpdate procedure to include authorization letter by supervisor
31-Jul-15
8.10.23.6 when an operator has not operated a trackless mobile machine for a period of two years, such operator is re-assessed to be competent by a competent person prior to being issued with a new license.
GG/OPI/B01.017 7.4.4 stipulate retesting is conducted once a year
Y
Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Physical Criteria
43
FAT % 6% of Index Rating
Aerobic Capacity
Step Test
Flexibility
Shoulder
Sit and reach
Muscle Strength
Back strength
Leg strength
Arm strength
Grip strength
Endurance
Abdominal
Shoulder
Leg
Test Battery - Physical Ability Testing
26% of Index Rating
Physical work capacity (PWC) = 29%23% of Index Rating
17% of Index Rating Functional Testing = 71%
28% of Index Rating
Profession Rating /5 Profession Rating /5 Profession Rating /5 Profession Rating /5Artisan aid 4 Admin assistant 0 Foreman 2 0
High Risk Low Risk Medium Risk Low RiskBoilermaker 4 Blaster 2 General Worker 4 3
High Risk Medium Risk High Risk Medium RiskDiesel Mechanic 3 Blasting assistant 4 Loco driver 3 3
Medium Risk High Risk Medium Risk Medium RiskElectrician 4 Controller 1 Maintenance operator 3 2
High Risk Low Risk (Screen repairs) Medium Risk Medium RiskFitter 3 Coordinator 1 Operator 3 2
Medium Risk Low Risk Medium Risk Medium RiskForeman 3 Drill operator 3 Process controller 3 0
Medium Risk Medium Risk Medium Risk Low RiskHelper 2 Drilling helper 3 Senior Process controller 2 3
Medium Risk Medium Risk Medium Risk Medium RiskMaintenance operator/hel 4 Foreman 3 Shunted 3 4
High Risk Medium Risk Medium Risk High RiskMillwright 5 General worker 4 Yard master 3 1
High Risk High Risk Medium Risk Low RiskPainter 3 Geologist 3 2
Medium Risk Medium Risk Medium RiskPlanner 0 Geology assistant 2 5
Low Risk Medium Risk High RiskPlanning Clerk 1 Helper 2 3
Low Risk Medium Risk Medium Risk
Electrician/Master
Engineer
Foreman
Fitter/Master
General worker
Diesel mech
Summary Risk ProfileEngineering Summary Mining Summary Plant Summary Waterberg Summary
Admin/Planning assistant/ClerkArtisan aid
Assistant Surveyor
Auto electrician
Boilermaker/welder
Contract Specialist
Body fat Step Test Flexibility Sit & Reach Back Grip L Grip R Leg Arm Sit-Ups Push-Ups Squads
23 28 119 0 25 149 39 39 159 69 29 16 34
Body fat Step Test Flexibility Sit & Reach Back Grip L Grip R Leg Arm Sit-Ups Push-Ups Squads
23 28 119 0 25 134 34 34 149 59 24 11 29
Body fat Step Test Flexibility Sit & Reach Back Grip L Grip R Leg Arm Sit-Ups Push-Ups Squads
23 28 119 0 25 119 29 29 139 54 19 7 19
High Risk
Medium Risk
Low Risk
Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Psychological Criteria
44
PSYCHOMOTORIC
Vienna Test Systems (Psychomotoric Assessment)
VTS is a computer aided assessment battery for machine and equipment operators. This battery
assesses the psychomotoric alertness of such employees and came into being when low-level labour-
intensive techniques were replaced by mechanization, both in underground and surface mining.
VTS is a reliable and objective battery that assesses operators for skills required to safely operate
mining equipment.
The VTS measures the following skills;
• Eye-hand, eye-foot and auditory perception,
• Two-hand co-ordination
• Spatial perception
• Glare recovery or visual accuracy with concentration
• Speed and distance estimation
Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Physical Criteria
45
The skills mentioned above were identified as essential for the safe, efficient and repeated successful
operation of modern mining equipment in Trackless, Conventional, Open – cast and Dredging mining.
The benefits of using the VTS are:
• Selection decisions can be quantified through research and statistics.
• Operators who are a safety risk can be identified beforehand
• People with risk behaviour can be out selected even before entering the system
• Loss in production, damages to expensive equipment and possible injuries by identifying risk operators can be minimized
• After evaluation of an employee it can be determined why an incident took place (e.g. Under estimation of speed / distance, etc).
• Selection Criteria A – High Risk / Fast Moving Equipment; B – Medium Risk / Slow Moving Equipment; C- Not recommended.
Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators
46
Init & Surname:
Employee No:
Equipment Type Authorisat Type
Employee Signature
Authorised by Signature
Expiring date
I-Permit Operate 2019-12-07
Overhead Crane Operate 2015-06-27
Safe Lifting Practice
Operate 2015-05-23
0
0
0
0
0
0
0
0
AUTHORISATION PERMIT FOR MACHINERY/EQUIPMENT IN TERMS OF THE MINE
HEALTH AND SAFETY ACT 29 OF 1996, AS AMENDED
You are hereby authorised by the Employer to operate/maintain/clean or repair MACHINERY/EQUIPMENT as listed below in accordance to the
Mine Health and Safety Act 29 of 1996, as amended. Approval of authorisations by appointed Managers / Engineers / Superintendent
(2.13.12) in terms of delegate of Section 7(2) and 7(4) of the Act.
R.D MASIMONG20070803
Init & Surname:
Employee No:
Dated Issued
Equipment Type Authorisat Type
Employee Signature
Expiring date
777 Low Bed Operate 2016-02-25Articulated Dump Truck
Maintain 2016-02-26Excavator BELL 1023
Repair 2016-02-27
FEL Le Tourneau Operate 2016-02-28
Euclid 190 Operate 2016-02-26
Euclid 200 Repair 2016-02-26
Grader 16M Operate 2016-02-26Articulated Service Truck
Operate 2016-02-26
2014-02-25
Authorised by Signature
TRACKLESS MOBILE MACHINE LICENSE CARDYou are hereby authorised by the responsible Engineer to operate
Trackless Mobile Machines as listed below in accordance to the Mine Health and Safety Act 29 of 1996, Regulation 8.10.23.4. Approval of
authorisations by appointed Engineers (2.13.1 or 2.2.13.3.1) in terms of delegation of authority as per Section 7(2) and 7(4) of the Act.
Photo
W HOFFMANN6176420
Regulation Applicable
Regulation Applicable
Regulation Applicable
8.10.23.7 that every operator of trackless mobile machines is issued with a license containing at least the following: i) a photograph to
positively identify the operator;
ii) ii) the trackless mobile machine types which the operator may operate;
iii) date of issue and expiry date; and
iv) the operator's company identification number.
Current License Card
Proposed License Card
Audit : Summary : Selection, training, appointment and licensing of trackless mobile machine operators
47
Recommendations
Update TMM operator authorization procedure in line with MHSA regulation
8.10.23
Action Responsible Due date Comment Completion
Update procedure to include authorization letter by
supervisorWillem Hoffmann 31-Jul-15 Procedure to be sent out for
revision0%
Workshop new license card in l ine with new regulation on
MineWillem Hoffmann 31-Mar-15
Sessions held with SHEC, AME's and Supts and layout was
finalised100%
Gain buy in from Snr Machinery Inspector Limpopo n proposed
layoutWayne Mulligan 15-Apr-15
Sample sent to Limpopo Snr Machinery Inspector for
comments50%
Train Training staff of new License cards Willem Hoffmann 28-May-15 Awaiting Approved License Card 0%
Implemented new license card Willem Hoffmann 30-Nov-15Issue new Licence card as operators do re-training 0%
Action Plan
Audit Finding
Operators of trackless mobile machines are not authorized in writing by their supervisor. Current License do not display
operators photograph and the issue date of the l icense
Regulation
Selection, training, appointment and l icensing of trackless mobile machine operators
Presentation Philosophy and Content 48
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Amended MHSA Chapter 8 Regulation 49
Regulation Compliance Findings Actions Date
Pre-use inspection procedures N
TMM COP 8.10.2. & 8.10.3. 84% of all TMM types have a pre-use that was derived from a risk assessment to determine all safety devices that need to be checked before use. These pre-use also have the criteria to determine if the item is safe or unsafe for use. The rest of the TMMs are using a standard pre-use.
Complete 16% of pre-use for TMMs 31-Dec-15
Reversing over the edge of a stockpile Y
GG/OPI/B01.018 stipulates condition of dumps (stockpiles) and dumping procedures to ensure safe dumping. Dumps are sloped and berms are erected to prevent reversing over the edge
Inadvertent movement of the trackless mobile machine Y
TMM COP 8.15.1 refers to operating procedures which govern the safe parking of TMMs. Certain TMMs also use stop blocks in addition to park breaks based on a risk assessments
Mandatory carrying of license Y Current GG StandardCertain regulations not applicable Y Implemented as such
Audit : Data : Pre-use inspection procedures 50
8.10.24 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for inspecting trackless mobile machines immediately prior to use, which procedures must include: 8.10.24.1that the operator of the trackless mobile machines physically inspects and ensures that the brakes, lights and any other defined safety features and devices are functioning as intended prior to setting such trackless mobile machines in motion; 8.10.24.2 pre-use check lists that have to be completed by all operators of trackless mobile machines at the beginning of their shift. Such check lists must clearly identify all the components, features and functionalities to be inspected by the operator. For each component, feature or functionality, the check list must clearly indicate the pre-established criteria under which the trackless mobile machines may or may not be put in motion.
Pre-Use Checklist
Pre-Use Checklist Standard
Audit Comply Non-Compliance TotalPre-use Checklist 72 37 109
TMMs 993 194 1187% 84% 16%
Audit : Data : Inadvertent movement of the trackless mobile machine
51
8.10.26 The employer must take reasonably practicable measures to prevent inadvertent movement of any trackless mobile machine whilst parked.
Loading Gradient Stop Blocks Front Stop Blocks Rear Outer ResultEmpty Incline 0 1 FailedEmpty Incline 1 0 FailedEmpty Decline 2 0 PassedEmpty Incline 2 0 PassedEmpty Decline 0 2 PassedEmpty Incline 0 2 PassedLoaded Decline 2 0 FailedLoaded Incline 2 0 FailedLoaded Decline 0 2 PassedLoaded Incline 0 2 PassedLoaded Incline 2 2 PassedLoaded Decline 2 2 Passed
Presentation Philosophy and Content 52
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Audit : Data : Collisions between trackless mobile machines and pedestrians and trackless mobile machines
53
Collisions between trackless mobile machines and pedestriansPrimary Mining
activites
Service and Maintenance
Contractor Employee
Private Vehicles
8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a result of collisions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such collisions, such measures must include at least the following:
8.10.1.1 All electrically or battery powered trackless mobile machines, excluding shovels, bucket wheel excavators and overburden drills, must be provided with means to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the trackless mobile machine and the pedestrian must be warned of each other's presence by means of an effective warning. In the event where no action is taken to prevent potential collision, further means must be provided to retard the trackless mobile machine to a safe speed where after the brakes of the trackless mobile machine are automatically applied without human intervention.
N/A N/A N/A N/A
8.10.1.2 All underground diesel powered trackless mobile machines must be provided with means:8.10.1.2(a) to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the diesel powered trackless mobile machine and the pedestrian shall be warned of each other's presence by means of an effective warning; and
N/A N/A N/A N/A
8.10.1.2(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must fail to safe without human intervention.
N/A N/A N/A N/A
Audit : Data : Collisions between trackless mobile machines and pedestrians and trackless mobile machines
54
Collisions between diesel powered trackless mobile machinesPrimary Mining
activites
Service and Maintenance
Contractor Employee
Private Vehicles
8.10.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between diesel powered trackless mobile machines. At any opencast or open pit mine where there is a significant risk of such collisions, such measures must include:8.10.2.1 Every diesel powered trackless mobile machine must be provided with means to automatically detect the presence of any other diesel powered trackless mobile machine within its vicinity; and
N N N/A N/A
8.10.2.1(a) upon detecting the presence of another diesel powered trackless mobile machine, the operators of both diesel powered trackless mobile machines shall be warned of each other's presence by means of an effective warning; and
N N N/A N/A
8.10.2.1(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must "fail to safe" without human intervention.
Not Yet in Force
Not Yet in Force
N/A N/A
Collisions between trackless mobile machines and rail bound equipment8.10.2.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between trackless mobile machines and rail bound equipment. At underground operations where there ie a significant risk of such collisions, such measures must include warning the operators of the trackless mobile machine and the locomotive of each other's presence by means of an effective warning.
N/A N/A N/A N/A
Significant Risk Evaluation Process 55
TMM Type Approximate QuantityPrimary Mining activites 145
Service and Maintenance 445Contractor 74
Employee Private Vehicles 419
Area Identification Hazard Identification Risk Identification and Assessment Raw Rating Controls Residual Rating
Geographical area Hazard Activity Risk (Unwanted event) Consequences
Co
nse
qu
en
ces
Lik
eli
ho
od
Ra
w R
ati
ng
Controls
Co
nse
qu
en
ces
Lik
eli
ho
od
Re
sid
ua
l R
ati
ng
Additional controls
Mining – Haul roads
Hauling on haul roads
Unauthorized use of equipment Fatality, Major damage 5 4 24
• Key control system for all equipment
• Training • Procedures • Supervision
5 2 19
Failure to use safety belts on trucks/TMMs
Fatalities, serious injuries 5 3 22
• Training • Safety belts should be worn at
all times • Mindset of an operator while
on duty • procedures
5 2 19
Slip and fall while Ascending or descending a haul truck Serious injuries 3 3 13
• Procedure and correct PPE • Training • Make sure that there’s enough
light during the night • Use of a Three point anchor
method • Housekeeping: No Foreign
objects on the walkways
3 2 9
Driving through water of unknown depth Injury, Major damage 3 4 17
• TMM operator should communicate with foreman/pit worker when encountering water of unknown depth
• Awareness of area before drive through.
• Determine depth of water before attempting to drive through.
• Procedures.
3 2 9
Interaction between equipment and structures /
power lines
Fatality, Electric shock, major damage 5 5 25
• Inspection of roads, loading and dumping areas during shift
• Awareness of structure’s positions near roads
• Demarcation on roads to guide traffic – leads, poles, etc.
• Safety berms to be placed in high risk areas
5 3 22
226 / 1187 Require PDS
56 Risk Assessment : Geographical Environment
Open Pit (Red Permit) Area:
• Mining Activities • TMM KE < 60MJ
• Haulers 200T Class • Blasting
• Major TMM Related Incidents
Plant Areas:
• TMM KE < 12MJ
• TMM Designated Areas of Operation
• Minor TMM Related Incidents
Office Area: • LDV Traffic Area
• Designated Parking • Demarcated
Pedestrian Crossing • No TMM Incidents
Access to Green Areas Service Station
Main access shared by LDV and Coal Trucks
Slow Moving TMM Operators Relieve And others activities
Risk Assessment : Evaluation Matrix 57
1. Hazard Identification 2. Risk Identification
3. Risk Analyses 4. Consequence & Likelihood
5. Identify High Risk 6. Control Measures (1-9)
7. Residual Risk 8. Implement Control Measures
9. Significant Risks - PDS
RISK ASSESSMENT PROCESS RISK ASSESSMENT PROCESS
Significant
Risk
Risk Assessment : Past Collision Data
Safety Performance
58
Haul Truck30%
Shovel14%
ADT1%
Dril l Rig4%
Diesel Bowser1%
LDV15%
Water Bowser2%
Grader3%
FEL2%
Track Dozer
1%
Rubber wheel Dozer
4%
Man - Service trucks
3%
Busses0%
Pedestrian0%
Stationary object20%
5 year historical of TMM type involved in collision incidents in mining
Risk Assessment : Past Collision Data
Safety Performance
59
2010 2011 2012 2013 2014P_HME 6 32 21 29 18S_HME 2 6 5 8 11LDV / Busse / Services 5 3 2 10 21Pedestrians 0 0 0 0 0Stationary Objects 10 10 16 6 2
0
5
10
15
20
25
30
35
Num
ber o
f inc
iden
ts
Summary of TMM, Pedestrians & Stationary objects involved in incidents
Risk Assessment : Open Pit TMM Collisions Summary
60
Section Possible TMM Collision Pairs
Highest Inherent (Raw) Risk
Highest Residual (Post Control) Risk
Target Risk (Post action Plan)
Open Pit Area
Haul Roads 738 25 25 19
Loading Areas 516 25 22 19
Drilling Blocks 25 22 22 19
Discard 381 25 19 15
IPCC 497 25 19 15
1300/1400 382 25 19 15
Niertjie 375 25 19 15
Blasting Area 25 19 19 15
Construction & Road Maintenance 738 25 25 19
Tipping Bins 348 25 24 19
Stockpiles 375 25 22 19
Workshops 627 25 25 19
Green Area Hauling 250 25 22 19
Green Area Secondary 250 25 22 19
Explosives Magazines 12 19 19 15
Risk Assessment : Plant Area TMM Collisions Summary
61
Section Possible TMM Collision Pairs
Highest Inherent (Raw) Risk
Highest Residual (Post Control) Risk
Target Risk (Post action Plan)
Open Pit Area
Beneficiation Plant 580 23 20 13
Central 396 23 17 13
Supply Chain 147 23 17 13
Risk Assessment : Mining Red Area TMM Collisions
63
Area: Haul RoadsIn
here
nt R
isk
Haul
Truc
ks
Grad
ers
Wat
er Tr
ucks
LDVs
Trac
k Doz
er
Whe
el Do
zers
824
Whe
el Do
zers
tiger
FEL (
large
)
FEL (
small
)
Exca
vato
r
TLB
Dies
el Bo
wser
Hone
y suc
ker
ADT S
ervic
e tru
ck
Low
Bed 7
77
Low
Bed s
ervic
es
Was
te tr
uck
Tyre
hand
ler
Cable
hand
ler
Trac
tor b
room
Fork
lift
Mob
ile cr
anes
Road
com
pacto
r
Craw
ler
Titan
Pant
o Plat
form
Cher
ry pi
cker
Mot
ivato
r
MAN
Cher
rypic
ker
MAN
Serv
ice tr
uck
Buss
es
Mini
-bus
/ tro
oper
Explo
sives
truc
ks
ADT W
ater
truc
k
Bob C
at
Drill
Rig
Shov
el
Stru
cture
s/bu
lding
s
Perso
ns
Haul Trucks 25 24 24 25 18 22 9 9 22 22 22 22 22 22 18 22 19 19 22 22 22 22 22 19 19 19 22 22 22 22 25 22 22 22 9 19 25 25Graders 14 22 22 13 9 22 14 14 5 5 22 22 13 22 22 19 19 22 22 22 22 19 5 22 19 18 9 9 22 22 22 18 22 9 19 22 22Water Trucks 22 22 17 17 17 8 8 19 19 22 22 22 24 24 19 19 22 22 22 22 22 18 22 22 21 22 22 22 22 21 19 22 18 19 25 22LDVs 20 14 22 22 22 22 5 5 22 22 22 22 22 2 19 19 22 22 22 14 14 22 19 22 22 22 22 21 19 21 13 18 5 25 22Track Dozer 9 9 9 14 14 14 14 22 19 13 9 14 19 3 5 14 3 22 18 18 22 19 14 10 14 22 15 19 14 19 9 3 19 22Wheel Dozers 824 9 22 18 18 13 9 22 18 18 22 22 6 6 13 13 9 14 9 9 22 14 22 22 22 22 22 22 13 22 9 9 18 22Wheel Dozers tiger 9 13 13 22 22 22 22 18 13 13 18 18 18 22 22 22 19 6 13 19 8 8 8 22 22 22 8 22 14 3 13 22FEL (large) 5 9 22 22 22 18 18 13 13 18 18 18 22 22 22 22 6 13 15 13 13 18 22 22 22 18 22 14 3 13 22FEL (small) 13 9 9 22 9 18 19 19 14 14 14 18 22 22 13 3 14 14 19 14 14 22 22 22 18 22 9 6 13 22Excavator 9 5 22 18 18 18 18 14 14 14 13 13 18 13 8 18 14 18 18 18 22 22 22 18 22 5 5 9 22TLB 14 22 19 18 18 18 18 13 13 13 13 18 13 5 18 13 18 18 18 22 22 22 18 22 5 5 13 22Diesel Bowser 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22Honey sucker 14 18 18 18 18 18 18 2 22 22 18 3 9 9 18 18 18 22 22 22 18 22 9 9 18 22ADT Service truck 0 18 18 18 18 18 22 22 18 18 5 9 13 18 18 18 22 22 22 18 22 13 6 18 22Low Bed 777 0 18 18 13 13 22 22 18 19 5 9 18 18 18 18 22 22 22 18 22 14 6 13 22Low Bed services 18 18 13 13 22 22 18 18 5 9 18 18 18 18 22 22 22 18 22 14 6 13 22Waste truck 0 18 18 22 22 22 18 5 13 18 18 18 18 22 22 22 18 22 9 1 13 22Tyre handler 18 13 13 18 18 18 5 18 18 18 18 18 22 22 22 18 22 9 1 13 22Cable handler 13 13 18 18 18 5 18 18 18 18 18 22 22 22 18 22 9 1 13 22Tractor broom 13 13 22 13 5 13 13 18 18 18 22 22 22 18 22 9 5 13 22Forklift 13 13 13 5 22 18 18 18 18 22 22 22 18 22 9 5 13 22Mobile cranes 22 18 5 18 18 18 13 13 22 22 22 18 22 13 9 13 22Road compactor 9 5 13 18 18 13 13 22 22 22 18 18 9 5 9 22Crawler 0 6 6 6 6 6 6 6 6 6 6 6 6 6 22Titan Panto Platform 0 18 18 18 18 22 22 22 18 22 9 6 22 22Cherry picker 5 18 18 18 22 22 22 18 6 6 6 13 22Motivator 0 18 18 22 22 22 18 22 6 18 17 22MAN Cherrypicker 9 18 22 22 22 18 22 6 8 13 22MAN Service truck 22 22 22 22 22 22 13 9 13 22Busses 22 22 22 22 22 6 9 18 22Mini-bus / trooper 22 22 22 22 6 9 18 22Explosives trucks 22 22 22 22 22 22 22ADT Water truck 0 22 9 9 13 22Bob Cat 4 4 3 5 18Drill Rig 3 3 13 25Shovel 3 13 18
Resid
ual R
isk
Haul
Truc
ks
Grad
ers
Wat
er Tr
ucks
LDVs
Trac
k Doz
er
Whe
el Do
zers
824
Whe
el Do
zers
tiger
FEL (
large
)
FEL (
small
)
Exca
vato
r
TLB
Dies
el Bo
wser
Hone
y suc
ker
ADT S
ervic
e tru
ck
Low
Bed 7
77
Low
Bed s
ervic
es
Was
te tr
uck
Tyre
hand
ler
Cable
hand
ler
Trac
tor b
room
Fork
lift
Mob
ile cr
anes
Road
com
pacto
r
Craw
ler
Titan
Pant
o Plat
form
Cher
ry pi
cker
Mot
ivato
r
MAN
Cher
rypic
ker
MAN
Serv
ice tr
uck
Buss
es
Mini
-bus
/ tro
oper
Explo
sives
truc
ks
ADT W
ater
truc
k
Bob C
at
Drill
Rig
Shov
el
Stru
cture
s/bu
lding
s
Perso
ns
25 24 24 25 15 19 9 9 19 19 19 19 15 19 14 15 15 15 19 19 19 15 19 10 15 15 19 19 19 15 19 19 19 19 9 5 22 2210 15 19 9 9 15 10 10 5 5 19 15 9 15 15 15 15 15 19 15 15 15 5 15 15 14 9 9 15 15 19 14 19 9 15 19 19
15 19 13 13 13 8 8 15 15 15 15 15 19 19 15 15 19 19 19 19 19 10 15 15 18 15 19 15 19 18 15 19 18 19 25 2220 10 15 15 15 15 5 5 19 15 15 15 15 2 15 15 19 15 15 10 10 15 15 15 15 15 15 18 15 18 9 6 5 22 15
9 9 9 10 10 10 10 15 15 9 9 10 15 3 5 10 3 15 10 10 15 15 10 10 10 15 15 15 10 15 9 3 15 159 15 14 10 6 6 15 10 14 15 15 6 6 6 6 9 10 9 9 15 10 15 15 15 15 19 19 6 15 9 9 14 15
9 9 9 15 15 15 15 14 6 6 10 10 10 15 15 15 15 6 6 15 8 8 8 15 15 15 8 15 10 3 6 155 9 19 19 19 15 15 9 9 14 14 14 19 19 19 19 6 9 9 9 9 14 19 19 19 14 19 10 3 9 15
9 9 9 15 9 14 15 15 10 10 10 14 19 19 9 3 10 1 15 10 10 15 19 1 14 19 9 6 9 199 5 15 14 14 14 14 10 10 10 9 9 10 9 8 10 10 14 14 14 15 15 19 14 15 5 5 9 15
10 15 15 14 14 14 14 9 9 9 9 9 9 5 9 9 14 14 14 15 19 15 14 15 5 5 13 1519 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19
10 14 14 14 14 14 14 2 15 15 14 3 9 9 14 14 14 15 15 15 14 19 9 9 14 190 14 14 14 14 14 19 19 14 14 5 9 9 14 14 14 19 19 19 14 19 9 6 14 19
0 14 14 9 9 15 15 14 15 5 9 14 14 14 14 15 15 15 10 10 10 6 9 1914 14 9 9 15 15 14 15 5 9 14 14 14 14 15 15 15 10 10 10 6 9 19
0 10 10 15 15 15 14 5 9 10 10 10 10 15 15 15 10 10 9 1 9 1915 9 9 14 14 14 5 14 14 14 14 14 19 19 19 14 19 9 1 9 19
9 9 10 10 10 5 10 10 10 10 10 15 15 15 10 19 9 1 9 199 9 15 9 5 9 9 10 10 10 15 15 15 10 15 9 5 9 19
9 9 9 5 15 10 10 10 10 15 15 15 10 15 9 5 9 1915 10 5 10 10 10 10 10 15 15 15 10 10 9 9 9 19
9 5 9 9 9 9 9 19 19 19 15 15 9 5 9 190 6 6 6 6 6 6 6 6 6 6 6 6 6 19
0 14 14 14 14 19 19 19 18 19 9 6 19 195 14 14 14 19 19 19 14 6 6 6 13 19
0 14 14 19 19 19 14 19 6 14 13 199 14 19 19 19 14 19 6 8 9 19
19 19 19 19 19 19 9 9 9 1919 19 19 19 19 6 9 14 19
19 19 19 19 6 9 14 1919 19 19 19 19 19 19
0 19 9 9 9 194 4 3 5 14
3 3 9 193 9 10
Risk Assessment : Plant Area TMM Collisions 64
Beneficiation Plant Ra
w ris
k
LDV
/ Tra
ilors
Coal
trans
porte
rs
Tar lo
ading
Tank
ers
Mob
ile Cr
anes
Trac
k Doz
er
Whe
el Do
zers
FEL
Mob
ile br
oom
Exca
vato
r
TLB
Self p
rope
lled D
iesel
Bows
er
Hone
y suc
ker
ADT
Low
Bed
Was
te tr
uck
Ambu
lance
Fire t
ruck
Fork
lift
Horse
& Tr
ailer
Road
com
pacto
r
Man
iscop
ic
Cher
ry pi
cker
Wat
er tr
ucks
Buss
es
Mini
-bus
/ tro
oper
Tippe
r tru
cks
Bob C
at /
Skids
teer
Grad
ers
Mob
ile Sc
reen
Stac
ker /
Recla
imer
s
Train
build
ings /
struc
ture
s / ov
erhe
ad ca
bles
Anim
als
Hum
an
LDV / Trailors 23 18 15 18 15 18 21 10 15 15 15 15 15 15 18 15 15 18 15 10 18 15 15 21 21 19 21 19 10 21 18 23 23 15Coal transporters 21 15 15 10 10 18 10 0 0 18 0 18 15 15 15 15 15 15 10 15 15 15 15 15 15 15 15 10 0 15 18 10 15Tar loading Trucks 0 15 0 0 15 10 0 15 15 15 15 15 15 15 15 15 15 10 15 15 15 15 15 15 15 0 0 0 0 15 10 15Mobile Cranes 21 15 15 15 10 15 15 15 15 15 21 15 15 15 15 15 15 15 10 15 15 15 15 10 15 10 15 15 21 10 15Track Dozers 0 0 15 0 0 0 15 0 0 15 0 15 15 0 0 0 0 0 0 0 0 0 0 0 0 15 0 18 10 15Wheel Dozers 0 15 0 0 0 15 0 0 0 0 15 15 0 0 0 0 0 15 0 0 0 0 0 0 15 0 14 10 15FEL 15 15 15 15 15 15 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 18 15 21 21 15Mobile broom 0 0 15 15 15 15 15 15 15 15 15 15 0 15 10 15 15 15 15 10 15 0 0 15 15 10 15Excavator 0 0 15 0 15 15 0 15 15 0 0 0 0 0 15 0 15 15 0 15 15 0 0 18 10 15TLB 0 15 15 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 15 15 18 10 15Self propelled Diesel Bowser 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 15 10 15Honey sucker 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 18 10 15ADT 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 10 15 15 10 15Low Bed 18 15 15 15 18 18 15 18 15 15 15 15 15 15 15 15 15 15 18 10 15Waste truck 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 15 10 15Ambulance 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 10 15Fire truck 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 10 15Forklift 18 18 15 15 15 15 15 15 15 15 15 15 15 15 21 10 15Horse & Trailer 15 15 18 15 15 15 15 15 15 15 15 15 15 15 10 15Road compactor 0 15 15 15 15 15 15 15 15 15 0 15 15 10 15Maniscopic 15 15 15 15 15 15 15 15 15 18 15 18 10 15Cherry picker 0 15 15 15 15 15 15 15 15 15 15 10 15Water trucks 15 15 15 15 15 15 15 0 15 15 10 15Busses 15 15 15 15 15 15 0 15 15 10 15Mini-bus / trooper 18 15 15 15 15 15 15 18 10 15Tipper trucks 21 15 15 15 15 15 18 10 15Bob Cat / Skidsteer 15 15 15 15 15 17 10 15Graders 0 15 0 15 15 10 15Mobile Screen 0 0 0 2 10 15
Resid
ual R
isk
LDV
/ Tra
ilors
Coal
trans
porte
rs
Tar lo
ading
Tank
ers
Mob
ile Cr
anes
Trac
k Doz
er
Whe
el Do
zers
FEL
Mob
ile br
oom
Exca
vato
r
TLB
Self p
rope
lled D
iesel
Bows
er
Hone
y suc
ker
ADT
Low
Bed
Was
te tr
uck
Ambu
lance
Fire t
ruck
Fork
lift
Horse
& Tr
ailer
Road
com
pacto
r
Man
iscop
ic
Cher
ry pi
cker
Wat
er tr
ucks
Buss
es
Mini
-bus
/ tro
oper
Tippe
r tru
cks
Bob C
at /
Skids
teer
Grad
ers
Mob
ile Sc
reen
Stac
ker /
Recla
imer
s
Train
build
ings /
struc
ture
s / ov
erhe
ad ca
bles
Anim
als
Hum
an
20 8 6 8 3 6 12 3 6 6 10 6 6 6 6 6 6 13 6 3 8 3 8 12 12 9 12 9 3 3 12 16 16 1012 3 3 3 10 10 10 0 0 10 0 13 6 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 0 6 13 3 10
0 6 0 0 6 10 0 6 10 6 6 6 6 6 6 6 6 3 6 10 6 6 6 6 6 0 0 0 0 6 3 1017 3 6 6 10 6 6 10 6 6 17 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 6 6 17 3 10
0 0 6 0 0 0 10 0 0 6 0 6 6 0 0 0 0 0 0 0 0 0 0 0 0 6 0 8 3 100 6 0 0 0 10 0 0 0 0 6 6 0 0 0 0 0 6 0 0 0 0 0 0 6 0 3 3 10
6 10 6 6 10 6 13 6 0 6 6 6 6 3 6 10 6 6 6 13 10 6 10 8 6 12 12 100 0 6 10 6 6 6 6 6 6 6 6 0 6 3 6 6 6 6 3 6 0 0 6 6 3 6
0 0 10 0 6 6 0 6 6 0 0 0 0 0 6 0 6 6 0 6 10 6 0 8 3 100 10 6 8 6 6 6 6 6 6 3 6 10 6 6 6 8 10 6 3 3 10 8 3 10
10 10 10 10 10 10 10 10 10 3 10 10 10 10 10 10 10 10 10 0 10 10 3 100 6 6 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 0 6 8 3 10
13 6 6 6 6 6 6 3 6 10 6 6 6 13 10 6 10 6 6 6 3 1013 6 6 6 13 13 3 13 10 6 6 6 6 10 6 10 6 6 13 3 10
0 6 6 6 6 3 6 10 6 6 6 6 10 6 10 0 6 6 3 100 6 6 6 3 6 10 6 6 6 6 10 6 10 6 6 6 3 10
0 6 6 3 6 10 6 6 6 6 10 6 10 6 6 6 3 1013 13 3 6 10 6 6 6 6 10 6 10 6 6 13 3 10
6 3 13 10 6 6 6 6 10 6 10 6 6 6 3 100 6 10 6 6 6 6 10 6 10 0 6 6 3 10
6 10 6 6 6 6 10 6 10 8 6 8 3 100 10 10 10 10 3 10 3 3 10 6 3 6
6 6 6 6 10 6 10 0 6 6 3 106 6 6 6 6 10 0 6 6 3 10
6 6 6 6 10 6 6 8 3 1017 10 6 10 6 6 8 3 10
3 10 3 3 10 12 3 60 10 0 6 6 3 10
0 0 0 2 3 6
65 Risk Assessment : Significant Risk Result
Open Pit (Red Permit) Area:
• PDS Required • Further action to
reduce risk
Plant Areas:
• PDS Not Required • Further action to
reduce risk
Office Area: • PDS Not required Access to Green Areas
Service Station
Main access shared by LDV and Coal Trucks
Slow Moving TMM Operators Relieve And others activities
Presentation Philosophy and Content 66
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
PDS Collision Risk Scenarios Addressed 67
1. 2.
3. 4.
5.
SAFE - MINE Project Scope 68
Function Detail
Traffic Awareness P_HME S_HME LDV
360∘ awareness, simple display
Safety Centre Shovel Assist
Tracking Radar Pedestrian (Only TMM will detect pedestrian)
Range up to 30m Detection of moving objects only Smart algorithm based collision Range up to 12 m Adapted to vehicle width Detection of static and moving
Geo - fencing Static Object Detection
NO – GO zones stop signs, overhead line Structures / buldings
Black Box Recording – Real Time
Continuous recording of vehicle parameters (speed, direction, braking)
Test / Sync Station, Boom Gates Testing
Assures protection and registers vehicles
Auto update of firmware and configuration
Equipment list covered in the project 69
Project Schedule Milestones 70
Task Name Duration Start Finish
PSO Setup 10 days Mon 15/05/04 Fri 15/05/15Project Planning 5 days Mon 15/05/18 Fri 15/05/22DMR Feedback Session 0 days Fri 15/05/22 Fri 15/05/22Contract Signature 0 days Mon 15/05/04 Mon 15/05/04Place Contract Orders 5 days Mon 15/06/08 Fri 15/06/12Site Establishment 33 days Fri 15/05/22 Wed 15/07/08Change Management 221 days Mon 15/05/25 Mon 16/03/28Critical Spares on Site 35 days Mon 15/05/04 Fri 15/06/19Installation Configuration Design
49.38 days Mon 15/05/25 Fri 15/07/31
Update of Procedures 90 days Fri 15/07/31 Fri 15/12/04Equipment Delivery 0 days Fri 15/07/31 Fri 15/07/31Installation 260 days Fri 15/07/31 Fri 16/07/29Activation 155 days Fri 16/01/29 Fri 16/09/02Training 160 days Fri 16/01/29 Fri 16/09/09
Audit : Summary : Collisions between trackless mobile machines and pedestrians and trackless mobile machines
71
Recommendations
Implement PDS on all TMMs operating in the red permit
area
Action Responsible Due date Comment CompletionInvolve H&S Committee to
evaluate TMM interactions according to MOSH risk assessment philosophy
Vicente Alvarado 15-May-15Sessions held with relevant H&S
committee members and risk assessment concluded.
100%
Compile Functional Specification for PDS
Henry Lefawane 15-Apr-15Sample sent to Limpopo Snr
Machinery Inspector for comments
100%
Complete Tender Process and award tender fro PDS
Johann Kruger 14-May-15Process conclude and Trysome
was awarding contract to install Safe mine PDS system
100%
Access to RBE (Spreader) in open pit is restricted but
requires PDSHenry Lefawane 09-Sep-16
Implement GEO fencing of Backfil l Spreader, CV10 and
MD100%
Implement PDS system Johann Flick 09-Sep-16 Kick-off meeting concluding site establishment in process
0%
Implement MOSH standard Adoption Change management
on PDSMadele Nelson 28-Mar-16 Scoping HR change management
project 0%
Regulation Audit Finding8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a
result of coll isions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such
coll isions, such measures must include at least thefollowing:
226/1187 TMMs require PDS
Action Plan
Presentation Philosophy and Content 72
H&S Committee
Vision & Purpose
Background
Presentation Philosophy
Amended MHSA Regulations Audit
Summary
Comply (83%)
PDS, CWA, TMM running out of control
ROPS, FOPS, Braking Systems
Restricted Visibility, Fatigue, Battery Charging,
Diesel Refuelling
Wheels, Access, Visibility, Unauthorized operation
Isolation, Operating, Maintenance, Remote TMM
Trailers, Towing, Roadways, Operator
Selection
Pre-use, Stockpile Reversing, Inadvertent
movement, carrying license, regulations N/A
Non-Compliance (17%)
Selection, training, appointment and licensing
of trackless mobile machine operators
Actions to Address Non-Compliance
Battery Charging Facilities Actions to Address Non-Compliance
Collisions between trackless mobile machines
and pedestrians and between trackless mobile
machines
Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure
DMR Section 54 Methodology
Audit current systems against new regulations (24/29=83% compliance)
Ensure current gaps are Fixed such gaps
Investigate systems failures
• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier
Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update
Reference : TMM Regulations
Summary and Closure 73
Based on the audit conducted on the new TMM regulations Exxaro Grootegeluk believes that the non-compliances identified and the action plans initiated will ensure that Grootegeluk complies with the new TMM regulations which will assist Grootegeluk in achieving our vision.
EXXARO reaffirms its commitment to strive for Zero Harm. An injury and fatality free company.
74
Backup Slides
Regulations
DMR Surface Mobile Equipment Interactive Risk Incident Review
MOSH T&M: Risk Analysis and Potential Leading Practice for Open Pit/Cast Operations
DMR Yardsticks
75
TMM Regulations 8.10.1 to 8.10.1.2 76
Collisions between trackless mobile machines and pedestrians8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a result of collisions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such collisions, such measures must include at least the following:8.10.1.1 All electrically or battery powered trackless mobile machines, excluding shovels, bucket wheel excavators and overburden drills, must be provided with means to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the trackless mobile machine and the pedestrian must be warned of each other's presence by means of an effective warning. In the event where no action is taken to prevent potential collision, further means must be provided to retard the trackless mobile machine to a safe speed where after the brakes of the trackless mobile machine are automatically applied without human intervention.8.10.1.2 All underground diesel powered trackless mobile machines must be provided with means:8.10.1.2(a) to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the diesel powered trackless mobile machine and the pedestrian shall be warned of each other's presence by means of an effective warning; and8.10.1.2(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must fail to safe without human intervention.
TMM Regulations 8.10.2 to 8.10.3 77
Collisions between diesel powered trackless mobile machines8.10.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between diesel powered trackless mobile machines. At any opencast or open pit mine where there is a significant risk of such collisions, such measures must include:8.10.2.1 Every diesel powered trackless mobile machine must be provided with means to automatically detect the presence of any other diesel powered trackless mobile machine within its vicinity; and8.10.2.1(a) upon detecting the presence of another diesel powered trackless mobile machine, the operators of both diesel powered trackless mobile machines shall be warned of each other's presence by means of an effective warning; and
8.10.2.1(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must "failto safe" without human intervention.
Collisions between trackless mobile machines and rail bound equipment8.10.2.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between trackless mobile machines and rail bound equipment. At underground operations where there ie a significant risk of such collisions, such measures must include warning the operators of the trackless mobile machine and thelocomotive of each other's presence by means of an effective warning.Trackless mobile machines running uncontrolled8.10.3 The employer must take reasonably practicable measures to prevent trackless mobile machines running uncontrolled.
TMM Regulations 8.10.4 to 8.10.7.4 78
Overturning of any trackless mobile machine8.10.4 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of overturning of any trackless mobile machine. Roll overprotection structures must be fitted on trackless mobile machines if required in terms of the mine's risk assessment.Objects falling onto operators and/or passengers of trackless mobile machines8.10.5 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of objects falling onto operators and/or passengers of trackless mobile machines. Trackless mobile machines must be fitted with falling object protection structures to protect operators and passengers from falling objects if required in terms of the mine's risk assessment.Persons inadvertently falling out of or being ejected from trackless mobile machines.
8.10.6 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of operators and/or passengers inadvertently falling out of or being ejected from any trackless mobile machine in motion.
Braking systems8.10.7 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of brake failure. Such measures must include ensuring:8.10.7.1 that trackless mobile machines are operated with adequate and effective braking systems;8.10.7.2 all braking systems are adequately and routinely tested for intended functionality;8.10.7.3 all braking systems are regularly maintained; and 8.10.7.4 that where a combined braking system is used, the design of the braking system is such that it complies with the requirements for the separate systems and that it fails to safe.
TMM Regulations 8.10.8 to 8.10.11 79
Restricted operator visibility.8.10.8 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of restricted operator visibility.Fatigue while operating a trackless mobile machine.8.10.9 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of fatigue of operators. Such measures must include a fatigue management procedure for operators.Battery charging facilities8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following:
i) Adequate through ventilation;ii) Adequate fire suppression equipment;iii) Effective provisions to treat persons in the event of acid spillage; andiv) Appropriate and adequate lighting.Diesel refuelling facilities8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following:i) Adequate through ventilation;ii) Adequate fire suppression equipment;iii) Effective provisions to cater for oil and diesel spillages; andiv) Appropriate and adequate lighting.v) Surface diesel refueling facilities are in accordance with:a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulkinstallations.
b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector.
c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.
TMM Regulations 8.10.12 to 8.10.15 80
Wheels, tyres and rims8.10.12 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented to prevent persons from being injured as a result of the use, storage and handling of wheels, tyres and rims.Access of persons to and from the trackless mobile machines8.10.13 The employer must take reasonably practicable measures to ensure that trackless mobile machines are designed, constructed and maintained such that persons getting on and off, or working on them can do so safely.Visibility of trackless mobile machines, skid mounted machinery and trailers to persons.8.10.14 The employer must take reasonably practicable measures to ensure that trackless mobile machines, skid mounted machinery and trailers are visible to persons in their vicinity.Unauthorised access to or operation of trackless mobile machines.8.10.15 The employer must take reasonably practicable measures to ensure thatunauthorised persons do not ride on or operate trackless mobile machines.
TMM Regulations 8.10.16 to 8.10.19 81
Isolation and lock-out of trackless mobile machines8.10.16 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the safe isolation and lockout of trackless mobile machines.Operating procedures8.10.17 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the safe operation of trackless mobile machines.Maintenance standards and procedures8.10.18 The employer must take reasonably practicable measures to ensure that procedures and standards are prepared and implemented for maintaining trackless mobile machines in a safe operating condition.Remote and remotely controlled trackless mobile machines8.10.19 The employer must take reasonably practicable measures to ensure that remote control devices for trackless mobile machines using a wireless remote control device comply with:a) SANS 61000-4-2 (IEC 61000-4-2) Electrostatic immunity discharge test;b) SANS 61000-4-3 (IEC 61000-4-3) Radiated, radio frequency, electromagnetic field immunity test;.c) SANS 61000-4-4 (IEC 61000-4-4) Electrical fast transient/burst immunity test;d) SANS 61000-4-5 (IEC 61000-4-5) Surge immunity test.e) SANS 61000-4-6 (IEC 61000-4-6) Immunity to conducted disturbances, induced by radio-frequency fields;f) SANS 61000-4-8 (IEC 61000-4-8) Power frequency magnetic field immunity test; and.g) SANS 61000-4-11 (IEC 61000-4-11) Voltage dips, short interruptions and voltage variations immunity test.
TMM Regulations 8.10.20 to 8.10.23.6 82
Trailers8.10.20 The employer must take reasonably practicable measures to ensure that:a) the design and construction of any trailer is in accordance with specifications approved by a competent person, which specifications must take into account the intended use of the trailer;b) the design and construction of trailer coupling and uncoupling mechanisms is such that coupling and uncoupling can be done safely and that no inadvertent uncoupling of the trailer can take place; andc) procedures are prepared and implemented for the safe operation of trailers.Towing and recovery of trackless mobile machines8.10.21 The employer must take reasonably practicable measures to ensure thatprocedures are prepared and implemented for the safe recovery and towing oftrackless mobile machines.Roadway conditions8.10.22 The employer must take reasonably practicable measures to ensure that the design, construction and maintenance of roadways are appropriate for the type and category of trackless mobile machineSelection, training, appointment and licensing of trackless mobile machine operators8.10.23.1 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the selection, training, appointment and licensing of trackless mobile machine operators, which procedures must include:8.10.23.1 physical and psychological pre-selection criteria;8.10.23.2 a training programme for trackless mobile machine operators, covering:i) theoretical training in a training Centre;ii) practical training; andiii) on the job training.8.10.23.3 assessment of the trainee, on successful completion of the training programme, by a competent person;8.10.23.4 that only operators, assessed to be competent are authorised in writing by the responsible engineer to operate trackless mobile machines;8.10.23.5 that operators of trackless mobile machines are authorized in writing by their supervisor to operate trackless mobile machines. Such authorization must detail their duties, responsibilities, limitations and areas of operation.8.10.23.6 when an operator has not operated a trackless mobile machine for a period of two years, such operator is re-assessed to be competent by a competent person prior to being issued with a new license.8.10.23.7 that every operator of trackless mobile machines is issued with a license containing at least the following:i) a photograph to positively identify the operator;ii) the trackless mobile machine types which the operator may operate;iii) date of issue and expiry date; andiv) the operator's company identification number.
TMM Regulations 8.10.24 to 8.10.28 83
Pre-use inspection procedures8.10.24 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for inspecting trackless mobile machines immediately prior to use, which procedures must include:
8.10.24.1that the operator of the trackless mobile machines physically inspects and ensures that the brakes, lights and any other defined safety features and devices are functioning as intended prior to setting such trackless mobile machines in motion;
8.10.24.2 pre-use check lists that have to be completed by all operators of trackless mobile machines at the beginning of their shift. Such check lists must clearly identify all the components, features and functionalities to be inspected by the operator. For each component, feature or functionality, the check list must clearly indicate the pre-established criteria under which the trackless mobile machines may or may not be put in motion.Reversing over the edge of a stockpile8.10.25 The employer must take reasonably practicable measures to prevent any trackless mobile machine reversing over the edge of a stockpile or dump.Inadvertent movement of the trackless mobile machine8.10.26 The employer must take reasonably practicable measures to prevent inadvertent movement of any trackless mobile machine whilst parked. Mandatory carrying of license8.10.27 All operators of trackless mobile machines must have their originally issued license on their person whilst operating any trackless mobile machine.Certain regulations not applicable8.10.28 Regulations 8.10.23 and 8.10.27 do not apply to trackless mobile machines licensed under the National Road Transportation Act 2000 and not used for primary mining activities.
END of TMM Regulation Slides click on ? To return to presentation menu 84
85
86
87
END of Surface Mobile Risk Review click on ? To return to presentation menu 88
MOSH T&M: Risk Analysis and Potential Leading Practice for Open Pit/Cast Operations
MOSH T&M: Equipment Related Hazards 90
MOSH T&M: Operator Related Hazards 91
MOSH T&M: Information Related Hazards 92
MOSH T&M: Environment Related Hazards 93
MOSH T&M: Operation Related Hazards 94
END of MOSH Slides click on ? To return to Significant Risk Evaluation Slide 95
DMR YARDSTICKS 96
1. Fatigue Management 2. Pre-Use Checklists 3. Roll-Over Protection Systems (ROPS) 4. Falling Objects Protection Systems (FOPS) 5. Procurement 6. Checklist of all TMMs 7. Pedestrian Detection (PD) System 8. Anti Collision Devices 9. Brake Interlocking (Doors) 10. Contractors' Packs 11. Maintenance Systems 12. Brake Test Ramp 13. Fitness to Perform Work (Medical) 14. Fire Extinguishers 15. Fire Suppressions 16. Emergency Preparedness 17. Ergonomics Assessment 18. Illumination 19. Equipment Noise Monitoring
YARDSTICKS – Baseline HIRA 97
22 22
19
22 22
19
22
18 19
22 22
6
15
10
19 19
6
14
9 9
19 19
YARDSTICKS 98
YARDSTICKS 99
YARDSTICKS 100
YARDSTICKS 101
YARDSTICKS 102
YARDSTICKS ADDITIONAL IMPROVEMENT ACTIONS / INITIATIVES
103
YARDSTICK SPECIFIC ACTIONS TARGET STATUS
TMM RELATED 1. Random Vehicle audits to check condition and
compliance to standards. Monthly CONTINUOUS
2. CAS / PDS ????? IN PROCESS
CONTRACTOR MANAGEMENT
1. Contractor Management Department June 2014 COMPLETE
2. Contractor competence and authorizations off site Monthly CONTINUOUS
EMERGENCY PREPARDENESS AND RESPONSE
1. Investigating method to improve EPR process and outputs. March 2015 IN PROCESS
2. Realignment of Trauma and Fire Fighting team March 2015 IN PROCESS
3. Currently evaluating the EPR Instruction issued by DMR for compliance.
February 2015 IN PROCESS
HEALTH AND HYGIENE RELATED
1. TMM Illumination audits and surveys on a more frequent basis Monthly CONTINUOUS
2. Physical Ability Testing Monthly CONTINUOUS
YARDSTICKS ADDITIONAL IMPROVEMENT ACTIONS / INITIATIVES
104
YARDSTICK SPECIFIC ACTIONS TARGET STATUS
GMIRM STRATEGY Risk Management Program to support management of Yardsticks
1. GMIRM Training on all 4 levels of Management and Workforce. July 2015 IN PROCESS
2. Identify GG status on the Journey Model January 2014 COMPLETE
3. Implementation of Improvement Plans. March 2015 IN PROCESS
COMPLIANCE STRATEGY
1. Compliance actions analysis - Present August 2014 COMPLETE
2. Analyze past 2 years actions implemented for completeness.
September 2014 COMPLETE
3. Audit and rectify completeness of actions in specific areas Monthly CONTINUOUS
4. VFL sessions to evaluate behavior Weekly CONTINUOUS
5. Instructions to comply process Random CONTINUOUS
6. Internal Sec 54 / 55 process Random CONTINUOUS
END of YARDSTICKS click on ? To return to Audit Summary 105
106
END of Backup Slides click on ? To return to presentation menu 107