Mine Road Workshop 2011 Bms

8/13/2019 Mine Road Workshop 2011 Bms

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31st May 2011

Albert Scheepers - Manager Pre-strip & Contracts (BMA Blackwater Mine)

Richard Collier - Manager Safety (BMA Saraji Mine)

BMA’s journey to preventUncontrolled Heavy VehicleMovements.



Agenda

Slide 2

1 Introduction; BMA / Site (BWM/SRM) Overviews

2 Incident Observations

3 Initiative Focus Areas

4 Conclusions



Who is BMA?

BHP Billiton Mitsubishi Alliance (BMA) is Australia’s largest exporter of

seaborne metallurgical coal.

Our mines have a combined production capacity of more than 58 million

tonnes per year.

BMA supplies high quality coking coals, weak coking coals, Pulverised

Coal Injection (PCI) coals and thermal coals to domestic and

international customers.

BMA was formed in 2001 as a partnership between BHP Billiton and

Mitsubishi Development Pty Ltd.

Slide 3





Slide 5

Our Operations

Clean Up Australia Day





Introduction

Mobile Equipment incidents identified as top Principal

Hazard, with Loss of Control a major factor. BMA has

undertaken extensive work (last 12 months) in regards to:

• Design, Construction and Maintenance of Mine Roads;

• Reviewing Dust Suppression Procedures;• Application of emerging Equipment Technology

• Operator Training, Awareness and Accountability

BMA now has measures in place and/or scheduled which

we believe are leading industry practice.

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BMA Saraji – General Layout

Jacaranda

R17N/S

HCU

Acacia

R1AN/S

DY (Nth)

Bauhinia

R2N/S, 4N

DY(Nth)

Coolibah

Acacia

R0, R1

Dogwood

R8S

DY(Sth)

EbonyR9S, R11N/S

HCU,HCL, DY(Sth)

Fiddlewood

R13N/S

HCL

Hakea

R15N/S

DY(Sth)

Grevillia

R14N/S

P, HCL, DY(Sth)

Blue boxes are current water storesIndustrial Area, Administration

and Mining Offices, CHPP, ROM,

Train Load-out and TAMS siteentry

Slide 8



Operations Overview

Slide 9



Equipment Overview

Saraji

Equipment

Waste Material Fleets

• BMA – 4 fleets

• Contractor – 6 fleets

• Pre-strip Operations

• Topsoil Operations

• Procap & Wedge Operations

• Parting Operations• Mud Operations

Coal Mining Fleets BMA fleets utilised to Haul ~13Mt of coal

per annum.

Total Number EME Trucks onsite 85 – incl. water trucks and service trucks.

Total Volume Truck & Shovel Fleets FY12 ~63Mbcm

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BMA Blackwater Layout

Slide 11

Operating Footprint

CHPP and

Tailings Dam

Thermal

Coal Plant

Blackwater

Township

Administration

South Plant

Complex



Typical Excavation - Blackwater

Slide 12



Equipment Overview

Blackwater

Equipment

Waste Material Fleets

• BMA – 3 fleets

• Contractor – 10 fleets

• Pre-strip Operations

• Topsoil Operations

• Procap Operations

• Mud Operations

Coal Mining Fleets BMA and Contractor fleets utilised to Haul

~20Mton of coal per annum.

Total Number Trucks onsite 123 – incl. water trucks and service trucks.

Total Volume Truck & Shovel Fleets FY12 ~75Mbcm

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Agenda

Slide 14




4 Conclusions





Agenda

Slide 16




4 Conclusions





Improvement Initiatives

PEOPLE

Initiative HOC Comment

Training & Signoff of Water Truck

Operators including reduction in

number of authorisations,

Admin All water truck operators

reassessed and signed off on water

truck assessment.

Education & Hazard AwarenessReporting

Admin Ongoing communication withworkforce to highlight obligations to

report unsafe conditions.

Reinforce employee accountability Admin Application of Just Culture Process

where applicable. Holding peopleaccountable for their actions.

Use of Simulator for training Admin Scenario programming in a

controlled environment.

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Slide 19





Improvement Initiatives –Water Truck Compliance

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ENVIRONMENT


Phase 1 of trial: Sheeting trials

using competent material

Substitution Trialled the use of reject material,

gravel and Permian rock as road

sheeting

Phase 2 of trial: Sub-base ofPermian sandstone or better on all

circuits

Substitution Elimination of Tertiary haul roadsand sub-base

Phase 3:Use of thin layer of gravel

or reject on down ramps andcorners

Substitution Implemented

Grade control assessment and

action process

Admin Supervisor visual assessment

(Shift) and formal weekly grade

survey of all circuits.

Slide 23



Improvement Initiatives –Permian Capping (Saraji)

Sub-base capping of Tertiary material; road widening; grade control

Slide 24



Improvement Initiatives – Road Design

All haul roads constructed as per requirements of SOP –Road Design, Construction & Maintenance

Slide 25





Initiatives (W.I.P. - Blackwater)

INSPECTION AND ASSESSMENT


Develop a Risk Matrix for watering

which includes road gradient,

material type, camber and corners.

Admin Draft designed and consultation

with other BMA sites in progress.

Generate a TARP as part of SOPcovering Road Watering which

identifies safe and unsafe situations

by all CMW and actions to be taken

to manage.

Admin Draft designed and consultationwith other BMA sites in progress.

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D ft “Alb t S ”



Draft “Alberts Square”Design/Construction Matrix

Slide 28



Draft TARP (Blackwater)

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ORGANISATION


Vehicle Restrictions on Operating

Circuits

Separation Restrictions of non essential

vehicular interaction on operating

prestrip circuits

License Restriction &Justification Process

Separation Formal justification process in placeto administer Site LV permits

BMA reactivation of Luxor quarry

to access additional gravel

supplies

Admin Sustainable delivery of required

resources to maintain acceptable

level of riskCrushing facility for onsite

competent material

Admin Investigating the use of onsite

competent material as road base

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I t I iti ti R d d T ffi



Improvement Initiatives – Reduced Trafficand Interaction

Light Vehicle Licensing

• All employees and contractors must

provide written justification for LVpermit

• Many persons do not require

licenses now with 4WD buses in placefor on site transport

• HV/LV interaction minimised (permit

restrictions, go-line segregation,lookouts, SOP32 improvements)

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Agenda

Slide 32




4 Conclusions

Key Controls that we believe enable BMA



Key Controls that we believe enable BMAto achieve “an acceptable level of risk”

• People – holding accountable, awareness andeducation

• Equipment – state of art technology; standardisation

• Environment - running surfaces constructed withcompetent material; daily and weekly grade checks

• Procedures – Clear Work Instructions

• Organisational – minimise HV/LV interaction; planningto source/bank and placement of competent material.

Slide 33



Conclusions

• BMA’s journey to prevent uncontrolled movement ofheavy equipment incidents has resulted in measures,

which we believe, are leading industry practice.

• The initiatives, we believe, will ensure an acceptable

level of risk is achieved whilst delivering productiongains and reduced maintenance.

• There is no one “Silver Bullet” that will fix the problem,

rather a series of variables which need to be effectivelymanaged.

“ Manage the Risks or They will Manage You”

Documents

Mine Road Workshop 2011 Bms