NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Ex equipment in NSW Coal MinesEx equipment in NSW Coal Mines--

An Australian (NSW) regulators An Australian (NSW) regulators perspectiveperspective

John Francis WaudbySenior Inspector of Electrical EngineeringMine Safety Operations

IEC Ex Meeting – Shanghai, P.R. China – Sept 2006

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Overview of this presentationINTRODUCTION

Mining in NSWMine Safety Operations – Electrical Engineering Safety

Ex EQUIPMENT IN COAL MINESTypes of equipmentHistorical approachDamage to Ex equipment

THE REGULATOR AND IEC ExPrinciples for life cycle mangement of Ex equipmentIEC Ex supporting the regulator

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

CoalMetalliferousQuarryingSand DredgingOpals

Fatality rate = 1/yearLTIFR = 16 per million hoursLast fatality 26/07/2006Previous fatality 14/06/2005

Mining in NSWMining in NSW

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Coal Mining in NSWCoal Mining in NSWNumber of O/C mines = 38

Number of U/G mines = 37

$6 billion of coal exports

$400 million in royalties to the state government

Total production = 150,000,000 tonnes / annum

Total U/G production = 50,000,000 tonnes / annum

Total employment = 12,000

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Electrical Engineering SafetyElectrical Engineering Safety--

NSW Mining Regulators NSW Mining Regulators ApproachApproach

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

MINE SAFETY OPERATIONS: Engineering Approach

Ω System safety engineeringΩ Hierarchy of risk controlsΩ Hazard reduction precedenceΩ Risk controls are best

implemented at the design stage

Ω Provision of life cycle information

Ω Life cycle management

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Electrical Engineering Safety (EES)Electrical Engineering Safety (EES)

Vision:

A mining industry that has eliminated death and injuries from

electrically powered and electrically controlled equipment.

Ω Prevention of gas and/or dust explosions,

Ω Prevention of electric shock and burns,

Ω Prevention of fires,

Ω Prevention of unintended operation of equipment,

Ω Provision of electrical safeguards.

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Coal Mining Coal Mining -- EES PerformanceEES Performance

Ω Last fatal accident 22 years ago

Ω Last electrocution 23 years ago

Ω Last fatal explosion 27 years ago

Ω Explosions / major gas ignitionsΩ 8/1/1979 - West WallsendΩ 24/7/1979 – AppinΩ 28/6/1995 - EndeavourΩ 12/12/1997 - Munmorah

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Ex Equipment in Underground Ex Equipment in Underground Coal MinesCoal Mines

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

415V Control station 415V Control station –– courtesy Ampcontrolcourtesy Ampcontrol

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Longwall –– Courtesy Westcliffe CollieryCourtesy Westcliffe Colliery

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall lighting and control Longwall lighting and control –– Courtesy DBTCourtesy DBT

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall chock control Longwall chock control –– Courtesy DBTCourtesy DBT

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall Shearer Longwall Shearer –– Courtesy Joy Courtesy Joy ManufacturingManufacturing

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall sub station Longwall sub station –– Courtesy AmpcontrolCourtesy Ampcontrol

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Longwall sub station Longwall sub station –– Courtesy AmpcontrolCourtesy Ampcontrol

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Transformer subTransformer sub--stationstation

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Bolter Miner Bolter Miner –– CoutesyCoutesy VoestVoest AlpineAlpine

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Bolter Miner Bolter Miner –– Courtesy Courtesy AustarAustar

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Roof bolting Roof bolting –– Courtesy Courtesy AustarAustar

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

RoadheaderRoadheader –– Courtesy Courtesy VoestVoest AlpineAlpine

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Continuous Miner Continuous Miner –– Courtesy Joy ManufacturingCourtesy Joy Manufacturing

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Continuous Miner Continuous Miner –– Courtesy MSHACourtesy MSHA

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Continuous Miner Continuous Miner –– Courtesy MSHACourtesy MSHA

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Miner loading a shuttlecar Miner loading a shuttlecar –– Courtesy Joy Courtesy Joy ManufacturingManufacturing

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Miner loading a shuttlecarMiner loading a shuttlecar–– Courtesy Courtesy AustarAustar

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

ShuttlecarShuttlecar

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Aux Fan Aux Fan –– Courtesy Courtesy AustarAustar

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW Mining RegulatorsNSW Mining RegulatorsExperience with Ex EquipmentExperience with Ex Equipment

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

A short history of dealing with Ex equipment A short history of dealing with Ex equipment ––Equipment approvalEquipment approvalΩ From the early 1970’s Ex equipment was approved by the CICM

Ω Based on a test report

Ω Reviewed by a competent engineer

Ω Approval documents and approval number issued – no time limit

Ω Database of approvals kept

Ω Some approvals were issued with non - compliance to standards

Ω Approval was initially free

Ω Conditions of manufacture / use were specified

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– Ex repair and mine managementEx repair and mine management

Ω From the late 1970’s:Ω Ex repair workshops were approved

Ω Ex equipment workers - examined by the regulator

Ω Mine electrical engineers examined by the regulator

Ω Approval / competency schemes were credible

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– From approval to certificationFrom approval to certification

Ω Approval and competency schemes evolved

Ω Legislation embraced contemporary OH&S Management

Ω National certification schemes matured

Ω This changing mix + industry culture allowed changes to approval

Ω At this point in time the IEC Ex scheme commenced

Ω An interim step of accepting IEC Ex CoC’s from Australian CB’s

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

A short history of dealing with Ex equipment A short history of dealing with Ex equipment –– Hazardous area incidentsHazardous area incidents

Ω Evidence of arcing on U/G mining cables

Ω Failure of Ex properties of equipment

Ω We keep cable damage statistics

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

0

10

20

30

40

50

60

99 / 00 00 / 01 01 / 02 02 / 03 03 / 04 04 / 05

TOTAL

Enclosure – switchgear,JB, switchMotor – Including JB

Gland / Receptacle /PlugLight

Window

In Service Failure of Ex ApparatusIn Service Failure of Ex Apparatus

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

A Regulators ExpectationsA Regulators Expectations&&

IEC Ex SchemesIEC Ex Schemes

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Summary of a regulators point of view on Summary of a regulators point of view on Ex equipmentEx equipmentΩ Coal mine explosions are high risk events.

Ω Ex is a critical risk controlΩ Additional scrutiny is needed.

Ω The scrutiny must be credible

Ω Ex equipment must be Ex throughout its life.Ω When new, it is as good as it gets

Ω Ex supported by the correct regulatory requirements

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Principles for managing Ex equipment Principles for managing Ex equipment --Additional scrutinyAdditional scrutinyΩ The additional scrutiny must:

Ω be applied at the proper points of the equipment life cycle.

Ω support all activities throughout the life cycle.

Ω support the hierarchy of risk controls

Ω support the hazard reduction precedence

Ω provide for a level of risk less than or equal to what we do now

Ω recognise the harsh mining environment

Ω be competent

Ω be credible

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Principles for managing Ex equipment Principles for managing Ex equipment --Credible scrutinyCredible scrutinyΩ set standard

Ω consistent and repeatable

Ω competent people

Ω proper procedures

Ω fit for purpose equipment & facilities

Ω managed work environment suitable for detailed technical evaluation

Ω work environment where cost does not overly influence the testing approach, reporting and review.

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Principles for managing Ex equipment Principles for managing Ex equipment --Current & proposed NSW legislationCurrent & proposed NSW legislationΩ Legislation requires

Ω Application of the hierarchy of risk controls

Ω Ex equipment to be certified

Ω Suppliers of equipment to provide sufficient life-cycle information

Ω Requires mines to have Ex repairs done at licensed facilitiesΩ Licensed facilities to have competent people

Ω Requires mines to have a mine electrical engineer

Ω Requires mines to have an Electrical Engineering Management Plan

Ω Requires mines to establish electrical competency requirements

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?

Ω Incorrect design of Ex = explosions in minesΩ Standards of design

Ω Competent designers

Ω Third party design verification

Ω Confidence in the manufacture

Ω Ex equipment arrives at the mine in an Ex condition.

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?

Ω Ex equipment arrives at the mine in an Ex condition.

Ω Equipment is installed, commissioned, maintained & used properlyΩ Provision of information

Ω Independent assessment at design verification stage

Ω Selection, installation, commission, inspect and maintenance standards

Ω Competency for management of Ex

Ω Competency for install, commission, inspect, maintain and operate

Ω Independent assessment of competency

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

IEC Ex IEC Ex –– Support for the regulator? Support for the regulator?

Ω Ex equipment has a hard life at the mine

Ω Ex management dictates overhaul and repair

Ω Equipment overhauled and repaired back to its certified stateΩ Provision of information

Ω Repair and overhaul standards

Ω Independent assessment of competencies

Ω Independent assessment of workshops Ω Facilities, tools, equipment and measurement

Ω Work processes, competencies and management systems

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Summary Summary -- IEC Ex supporting the regulatorIEC Ex supporting the regulator

Ω The IEC Ex standards and IEC Ex schemes provide for:Ω hierarchy of risk controls

Ω hazard reduction precedence

Ω provision of information

Ω each element of the Nertney Wheel

Ω life cycle management

Ω appropriate independent assessment at appropriate points

Ω All of the above is required by contemporary OH&S legislation

Ω All of the above supports the aims of the Australian, NSW regulator

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

IEC Ex supporting the regulator IEC Ex supporting the regulator –– the the current situationcurrent situation

Ω Currently the DPI:Ω is considering full acceptance of the IEC Ex scheme.

Ω has proposed full acceptance & canvassed industry comment

Ω Industry’s wishes will be implemented via a notice

Ω A decision will be made in 2006 or early 2007

Ω The regulator still retains prohibition powers

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

CONCLUSIONSCONCLUSIONSΩ The IEC Ex standards and schemes can aid:

Ω Life cycle management of Ex equipment

Ω The regulator’s aims for electrical engineering safety

Ω A mine operator’s fulfilment of OH&S obligations

Ω An equipment suppliers fulfilment of OH&S obligations

Ω Credibility of the schemes is a critical component

Ω We have our point of view and respect others

Ω We are committed to a highly credible IEC Ex scheme

NSW DEPARTMENT OF PRIMARY INDUSTRIESMINE SAFETY OPERATIONSMINE SAFETY OPERATIONS

Contact detailsContact details

Website: www.minerals.nsw.gov.au/safety

Email: john.waudby@dpi.nsw.gov.au