BATHOPELE MINE - amre.org.za€¦ · V4-Loss of Control 19 221 3 0.3 0.9 102 24 91 P4-Access &...
Transcript of BATHOPELE MINE - amre.org.za€¦ · V4-Loss of Control 19 221 3 0.3 0.9 102 24 91 P4-Access &...
BATHOPELE MINE AMRE
12 February 2015
TABLE OF CONTENTS
1. Introduction to the mine
2. CMSS project overview
3. Lamp Room Management System
4. Asset Tracking
5. Collision Warning System
3
LOCATION OF UG2 RUSTENBURG MINES
4
UNDERGROUND PLAN
Concentrator Silo
East # Central #
Surface Silo
6 Km
±30m BS
±500m BS
±350m BS
±200m BS
Joy Cutter
5
BUSINESS OVERVIEW – QUICK FACTS
• Mine started in 1999. Full Investment Proposal (IP)
production was reached in 2003 at 220ktpm.
• Life of Mine at current mining rates is until 2028.
• The mine applies a fully mechanised bord and pillar mining
method.
• Consists of two decline shafts namely East and Central
shafts.
• Low Profile mining between 195cm and 220cm stope width
delivers 90% of total tonnage.
• Extra Low Profile mining at 120cm stope width delivers the
remaining 10% of tonnage.
• Ultra Low Profile mining at 100cm stope width currently in
project phase.
• Approximately 31% and 22% of total Rustenburg tonnage
and platinum ounce production respectively are produced by
Bathopele.
6
BORD AND PILLAR LAYOUT– LOW PROFILE SUITE
East#
Central #
7
• 1 Section = 27 People
• 9 People per shift
• 2 x 11 ½ hr shifts/day
• 2400m²/Crew/Month @ 2.77g/t
• 89m²/TSE
• 32 Pt oz’s/TSE
LOW PROFILE EQUIPMENT
20 Holes/Hour 10 Loads/Hour
7 Bolts/hour
8
MINING LAYOUT FOR XTRA LOW PROFILE SUITE
Central #
9
XTRA LOW PROFILE SUITE EQUIPMENT
• 1 Section = 48 People
• 16 People per shift
• 2 x 11 ½ hr shifts/day
• 3000m²/Crew/Month @ 3.53g/t
• 63m²/TSE
• 29 Pt oz’s/TSE
10
OVERVIEW
11
LAMP ROOM MANAGEMENT
12
INNOVATION BUSINESS IMPROVEMENT
Detail – Cap lamp warning system
Lamp room management
• Ensures every U/G employee is
issued with a lamp, and assists with
shift clearance
• Messaging function
• Automatic Download of data
• Tracking function.
• Enhanced light & sound warning
function
13
PHASE I – LAMP ROOM MANAGEMENT
Required safety equipment will be
allocated to the person at the Auto
Allocation Bay
Safety Equipment Allocated?
No
Yes
CAS Test Unit
Lamp has LCD screen enabling PTC messaging (both directions) as well as distress call
Frames will block underground access if person not carrying all required allocated
safety equipment
14
ASSET TRACKING
15
PHASE II – IM INFRASTRUCTURE
Underground network: − Central and East Shafts − Declines and all active
strikes − Redundancy link
Underground network: − network enclosures installed every 200m in all
active strikes – hosts Schauenburg controllers which provide approximately 100m radius line-of-sight RFI coverage
− will be monitored 24/7 by IIT − will host all systems requiring underground
network connectivity − is “expansion ready” for any future requirements
16
PHASE I – PEOPLE TRACKING
Surface and
Underground
Antennas
and
Controllers
use RFI to
track assets
Surface Asset Tracking
Underground Asset Tracking
PTC Messaging (both directions) and Distress Call
17
COLLISION WARNING SYSTEM
LEGAL ASPECTS TMM • Implementation drive from DMR– Regulation
• 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
• 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 system on the diesel powered trackless mobile machine must fail to safe without human intervention.
The regulations, except sub-regulations 8.10.1.2(b) and 8.10.2.1(b), will come into force 3 months after the date of publication;
A further notice will be published at some time in the future to indicate when sub-regulations 8.10.1.2(b) and 8.10.2.1(b) will come into force;
The requirement to have PDS systems applies only in respect of: (i) mines where there is a significant risk of pedestrians being injured as a result of collisions between TMMs and pedestrians and (ii) opencast and open pit mines where there is a significant risk of injury as a result of collisions between diesel TMMs. It will therefore be important for mines to do proper risk assessments and have copies of them available at the mine to substantiate any decision as to whether or not PDS systems are required at the mine in terms of the regulations.
19
Incident Analysis Site Risk Assessment and
Safeguard Analysis
Scenario Evaluation
Define and Sign-off on
Collision Management Strategy
Implementation
Use the Group Specification as
the starting point
Risk Matrix
Recommended Process For CWS Implementation
20
SCENARIOS
21
COAL, SOUTH AFRICA UG
Scenario
#in
cid
ents
Wei
ghte
d
Ris
k
Rev
: 3
-10
Rev
: 0
-3
Stat
ion
ary
Fwd
: 0
-3
Fwd
: 3
-10
Fwd
: 1
0-3
0
184 30005 720 2523 5565 8485 5726 6986
P1-Person (direct) 113 19642 630 1800 5211 7622 4109 270
V4-Loss of Control 21 7030 0 133 324 193 810 5570
P3-Person (indirect) 44 2990 90 580 30 643 507 1140
O1-Obstacle 4 310 0 10 0 27 270 3
L5-Passing Head-on 1 30 0 0 0 0 30 0
V1-Void 1 3 0 0 0 0 0 3
Interactor
#in
cid
ents
We
igh
ted
R
isk
Person Equip-ment
Infra-structure
Un-controlled
PUE1 PUE2 PUE3 PUE4
184 30005 19588 1791 1099 7100
Continuous Miner 20 9644 9580 27 37 0
LHD Unit 65 7385 5548 1417 307 103
LDV 20 5805 93 40 56 5616
Shuttle Car / Hauler 26 3184 2478 27 282 37
Tractor 23 2589 694 270 344 1224
Roofbolter 15 777 734 0 43 0
Other 15 621 461 10 30 120
(N=119) (N=65)
22
COAL, AUSTRALIA UG
Scenario
#in
cid
ents
Wei
ghte
d
Ris
k
Rev
: 3
-10
Rev
: 0
-3
Stat
ion
ary
Fwd
: 0
-3
Fwd
: 3
-10
Fwd
: 1
0-3
0
92 1213 97 15 271 495 241 94
P1-Person (direct) 7 479 0 0 90 380 9 0
V4-Loss of Control 19 221 3 0.3 0.9 102 24 91
P4-Access & Egress 2 180 0 0 180 0 0 0
L5-Passing Head-on 10 128 0 0 0 0.9 123 3
T3-Intersection 13 125 91 1.1 0 0.9 33 0
L8-Blind Approach 9 33 1 0.9 0 3.3 28 0
V6-Congested Area 18 31 0.9 4.8 0 5.1 20 0
Other 14 16 0.9 7.5 0.3 2.2 3.9 0
Interactor
#in
cid
ents
Wei
ghte
d
Ris
k
Person Equip-ment
Infra-structure
Un-controlled
PUE1 PUE2 PUE3 PUE4
92 1213 758 320 130 5
Shuttle Car 8 470 460 0.4 10 0
LHD Unit 47 302 99 88 114 2
Continuous Miner* 2 180 180 0 0 0
Coal Hauler 6 111 9 101 0.9 0
Ramcar 3 92 0 92 0 0
Personnel Transporter 14 37 0 34 3.24 0
Feeder Breaker 1 10 10 0 0 0
Other 11 10 0 4.5 2.2 3
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PLATINUM, SOUTH AFRICA UG
(N=84) (N=34)
Scenario
#in
cid
ents
Wei
ghte
d
Ris
k
Rev
: 3
-10
Rev
: 0
-3
Stat
ion
ary
Fwd
: 0
-3
Fwd
: 3
-10
Fwd
: 1
0-3
0
118 17527 1000 1824 667 1803 6887 5346
P1-Person (direct) 62 7450 1000 1810 547 1601 2492 0
V4-Loss of Control 16 6655 0 3 0 103 1540 5009
L1-Head-on 4 1003 0 0 0 2.7 1000 0
L4-Dovetailing 1 1000 0 0 0 0 1000 0
P3-Person (indirect) 17 885 0 0 90 3 455 337
T3-Intersection 3 270 0 0 0 0 270 0
O1-Obstacle 8 132 0 10 10 2.7 110 0
L8-Blind Approach 3 100 0 0 0 90 10 0
P4-Access & Egress 2 20 0 0 20 0 0 0
L7-Overtaking 1 10 0 0 0 0 10 0
Interactor
#in
cid
ents
Wei
ghte
d
Ris
k
Person Equip-ment
Infra-structure
Un-controlled
PUE1 PUE2 PUE3 PUE4
118 17527 8596 2439 1008 5485
LDV 16 6776 183 1010 400 5183
LHD Unit 70 6291 5435 390 434 32
MPV 17 3056 2694 28 64 270
Personnel transporter 5 1120 90 1010 20 0
Roofbolter 8 194 194 0 0 0
Hydraulic drill rig 2 90.9 0 0.9 90 0
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INNOVATION BUSINESS IMPROVEMENT
PDS/VDS/CAS
• Persons U/G are warned of
approaching vehicles.
• Vehicle operators are warned
of pedestrians.
• Vehicles are warned of other
vehicles.
• Vehicles are slowed down
and/or stopped automatically
within certain zones.
25
INNOVATION BUSINESS IMPROVEMENT
PDS / CAS JOURNEY
• URS were drafted during 2012 and final approval of the project was in Nov 2013
• 2014 Development/Testing of technology
• During integration tests interference issues were picked up
• The mine requested vendors to conduct extensive independent tests at ITC and GEROTEK
• Vendor solutions was also piloted underground to verify the outcome of the independent tests
• The pilot results supported the independent test results
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
27
RELIABILITY: EXTERNAL RELIABILITY TESTS
28
RELIABILITY: INTERNAL RELIABILITY TESTS
RELIABILITY: URS Specification
Phase 3 CAS – VDS/PDS
Warning fields tested 25m
Slowdown tested 15m & 12m UG
Stop tested 5-7m
Side fields can be set close to vehicle Large
Space required for antennas Small
Susceptible to interference and therefore not always reliable No problem
Field setting reliable – tested same distance repeatedly Good
Field range adjustability Electronic
Future enhancements (e.g. machine diagnostics) can be easily incorporated
Yes
Radiative tests complete Yes
Phase 1 Lamp Room Management & Employee and Asset Tracking
People and Vehicle Tracking Yes
Employee PTC (Page/Tracking/Comms) Yes
Light Weight LED – Lithium Type Lamps Yes
Employee safety equipment blocking at turnstiles Yes
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
31
COST
NB! ALL NEW VEHICLES PROCURED SHOULD BE CAS READY
CAPEX COST % Total Cost Machine
Installation cost per TMM 2%
TMM CAS Ready Costs 4%
OPEX COST Running Cost
Maintenance Contract Dependant on Maintenance Contract
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
CHANGE MANAGEMENT • OEM and Mine Risk Assessment
• Design Risk Assessment
• Specifications/Standards/ COP Adoption
• Training and Induction Videos
• Traffic Management Plan to be revised:
‒ Impact on production ‒ Artisan override
• Culture (dependency on CAS)
• Phasing out old VDS/PDS System
• Ergonomics ‒ Cluttering of operator cabin ‒ Visibility chart per OEM had to be revised ‒ SBI
• Implementation Methodology
34
CHANGE MANAGEMENT: ERGONOMICS
Cluttering of Operator Cabin
35
CHANGE MANAGEMENT: ERGONOMICS
Visibility chart per OEM had to be revised and bracket fitment had to be approved per OEM
36
CHANGE MANAGEMENT: IMPLEMENTATION METHODOLOGY
Phased approach Target Date Step 1 : Multiple vendor implementation (fast-moving) Dec 2014 Step 2 : Training Dec 2014 Step 3 : Commission SCAS II (fast-moving) Dec 2014 Step 4 : Lamp room changeover Dec 2014 Step 5 : Activate VDS / PDS Dec 2014 Step 6 : Implementation and commissioning of slow-moving Mar 2015 Step 7 : Tracking and Monitoring Mar 2015 Step 8 : Messaging and Distress Calls Mar 2015 Step 9 : Asset management (turnstile blocking) Mar 2015 Step 10: Section approach to SCAS ready Aug 2015
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
INTERFACE • CAS / OEM
• Intelligent type vehicles
‒ OEM resistance due to legal implications
• Non-intelligent type vehicles
‒ Fourth party equipment needs to provide interface
• Communication between suppliers
‒ Digital / Manual Inputs
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
LEGAL ASPECTS: ACCOUNTABILITY
OEM vs Third Party (Schauenburg) vs Fourth party (Engine owner)
OEM
Third Party (CAS
System)
Fourth Party(Non Intelligent Machines)
Operator
COLLISION AVOIDANCE SYSTEM
Legal Aspects
Cost
Change Management
Production Impact
Interface
Reliability Collision
Avoidance System
42
PRODUCTION IMPACT
43
THE WAY FORWARD – SLOWDOWN OR STOP
The following operating environmental conditions should be considered for stop: • Temperature (Hydraulics) • Roadway conditions
• Inclination • Wet vs Dry
• Tramming speed of LHD • Rock strata affecting
radio frequency • Tyre conditions • Break efficiency • Legal implications when
serious incident occurs (operator will have no accountability)
44
PHASE III – VIDEO CLIPS
− Surface slow down and stop tests
− Underground slow down and stop tests
THANK YOU