Risk Management in UG Rail Transport in Gold · PDF file 2018. 3. 13. · • HT...

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Transcript of Risk Management in UG Rail Transport in Gold · PDF file 2018. 3. 13. · • HT...

  • 1

    IAIN MENZIES HEAD OF ENGINEERING Africa Underground Region

    Risk Management in Underground Rail Transport in Gold Mining

    July 2006

  • 2

    Risk – Peril Category Position – All Operations

    Enterprise-wide Risk Management Matrix

  • 3

    HT Risk – Enterprise Wide Risk Management

    HT Risk - Enterprise wide Risk Management

    27

    7 25

    9 12 31

    20

    76

    26

    148

    30 14

    1 20

    41 26

    50 29

    14 1

    32 41

    15 25 29 17

    1

    32 41

    15 25 29

    9 0

    0

    50

    100

    150

    GN KOP MK MP SAV TL TT

    R is

    k Va

    lu e

    Q1 05 Q2 05 Q3 05 Q4 05 Q1 06

  • 4

    The Loss Causation Model

    O perational C

    ontrol

    U nsafe A

    cts

    U nsafe C

    onditions

    System Controls

    R isk A

    ssessm ent

    Incident

    T hreshold Lim

    it

    Loss

  • 5

    U/G Horizontal Transport Fatalities

    3738

    2003200220012000

  • 6

    Vertical Shaft Incident

  • 7

    Vertical Shaft Incident

    Stop the shaft!

    What?

    Why?

    Team Investigation

    Risk assessment

    Design review

    Fix Monitor

  • 8

    Horizontal transport Incident

  • 9

    Horizontal transport Incident

    Loco team re-rails without proper equipment …

    No management investigation

  • 10

    Time Frame

    • HT Task Teams 2001/2002

    • 2003 Safety Strategic Session

    • 2003 Strategic Plan for HT Safety

    • 2004 Strategic Plan for HT & VT Safety

    • 2005 Strategic Plan for continuation of Transport Safety

    • 2006 Continuation of Transport Safety Initiatives

  • 11

    2003 HT STRATEGIC ISSUES

    Develop a set of non-negotiable golden rules for HT9

    OESH Person to be appointed for HT8

    Internal / External audits – to be conducted7

    Action plan to address issues6

    Conduct issue based risk assessments5

    Review baseline risk assessments4

    Appoint Eng. Manager as custodian of HT supported by senior operational line officials

    3

    Operational Guidance – Mike O’Hare2

    Technical & Progress – Iain Menzies1

  • 12

    Overall Thrust

    • Long Term Action Plans

    • Short Term Initiatives

  • 13

    HT HIGH LEVEL SAFETY INITIATIVES

    • HT Audits – 18 monthly by Audit department, 9 month follow up. • HT User Group meetings • Mine based HT Task Group • HT Guidelines and Standards in place and reviewed continuously. • Updated mine overseers COP’s for Engineering. • M/O and S/O Engineering awareness training. • Track work upgrading R7.7m over last 3 years, R10,8 for next 3 years. • Audit of all stope box fronts. • Issued HT Golden Rules. • HT action logs (general guideline developed) • Appointment of dedicated HT OESH persons. • Derailment reporting. • HT Safety competition. • Mobile equipment driver selection criteria. • Track work C.O.W. appointments. • Section Risk Ratings. • Review and action all major accidents • Improved maintenance techniques

  • 14

    HT HIGH LEVEL SAFETY INITIATIVES CONT.

    • Track work maintenance training course. • Standard (correctly designed) stope box front. • Pneumatic control of stope chutes. • Stope box front mud rush simulator. • Contractors check list. • Design work on rolling stock suspension systems. • New era loco programme 109 out of 426 • Six monthly safety workshop. • Video camera installation at strategic points. • Industrial Engineering simulations • Centre of gravity tramming • Large Locos/spans – reduction of fleet • Vent door design improvements. • Quarterly Business Unit feed back to Head of Engineering • Enhanced Reporting. • Process based organization.

  • 15

    HT Incident – Injury Classification (compare incidents with Risk Profile)

    AngloGold Ashanti - SA Operations HT Injury Classification

    0

    100

    200

    300

    400

    500

    600

    700

    800

    2003 2004 2005 2006 YTD

    Qrt 1 Qrt 2 Qrt 3 Qrt 4 Qrt 1 Qrt 2 Qrt 3 Qrt 4 Qrt 1

    2004 2005 2006

    Dressing Case Lost Time Serious Fatal

    Ang loGo ld As han ti SA Ope ra ti ons - Horizon ta l T ra ns port Av e ra ge Work pla ce Ri sk Rat ings

    0

    2 0

    4 0

    6 0

    8 0

    10 0

    12 0

    14 0

    20 03 20 04 20 05 20 06 YTD

    Q rt 1 Q rt 2 Q rt 3 Q rt 4 Q rt 1 Qr t 2 Qr t 3 Qrt 4 Qrt 1

    2 00 4 20 05 200 6

  • 16

    Horizontal Transport Fatalities

    8 2000

    3 2001

    7 2002

    3 2003

    1 2004

    02 20062005

  • 17

    Golden Rules of Tramming

    When last have you been for a refresher train ing

    Valid Driver Permit

    Do You Fill in Your Pre-Use Checklist Daily

    Checklist

    Do You Stand Clear From The Tracks When a Loco Approach

    Do You Report All Derailments And Incedents

    Do You Adhere To All Traffic Rules

  • 18

    Engineering HT & VT Competition - 2005

  • 19

  • 20

    Horizontal Transport Audits

    Horizontal Transport Audits 100% done in 2005

    0 20 40 60 80

    100

    TT MP SAV KP GN TL MK WW Mine Serv

    Met VR

    AGA Ave

    %

    2005 2004 2003

  • 21

    HT Risk Profiles (a)

    Great Noligwa - W orkplace Risk Ratings Horizontal Transport

    0

    20

    40

    60

    80

    100

    120

    140

    160

    2003 2004 2005 2006 YTD

    Qrt 1 Qrt 2 Qrt 3 Qrt 4 Qrt 1 Qrt 2 Qrt 3 Qrt 4 Qrt 1

    2004 2005 2006

  • 22

    HT Incidents – Job Factor Failures (c)

    SA Operations - Horizontal Transport Job Factors - 1st Quarter 2006

    0 10 20 30 40 50 60

    Inadequate supervision

    Inadequate standards of work (Include standards, training and compliance).

    Inadequate maintenance

    Inadequate mining or engineering design and/or methods

    Inadequate tools and equipment (incorrect type)

    Normal wear and tear

    Inadequate coaching/training

    No training

    Dressing Case Lost Time Serious

    O perational C

    ontrol

    U nsafe A

    cts

    U nsafe C

    onditions

    System C

    ontrols

    R isk A

    ssessm ent

    Incident

    Threshold Lim it

    Loss

  • 23

    HT Incidents – Job Factor Failures (d)

    Horizontal Transport - Job Factors Top 5 Distribution plus others

    0%

    10%

    20%

    30%

    40%

    50%

    60%

    70%

    80%

    90%

    100%

    2003 2004 2005 2006 Qtr1 Qtr2 Qtr3 Qtr4 Qtr1 Qtr2 Qtr3 Qtr4 Qtr1

    2004 2005 2006 Inadequate supervision Inadequate standards of work (Include standards, training and compliance). Inadequate maintenance Inadequate mining or engineering design and/or methods Inadequate coaching/training Other

  • 24

    HT Incidents – Personal Factor Failures (e)

    SA Operations - Horizontal Transport Personal Factors - 1st Quarter 2006

    0 10 20 30 40 50 60 70 80

    Incorrect judgement

    Improper attitude

    Inadequate/incorrect communication techniques

    Improper motivation

    Physical capability

    Inadequate/incorrect aptitude

    Dressing Case Lost Time Serious

    O perational C

    ontrol

    U nsafe A

    cts

    U nsafe C

    onditions

    System C

    ontrols

    R isk A

    ssessm ent

    Incident

    Threshold Lim it

    Loss

  • 25

    HT Incidents – Construction Hazards (f)

    Horizontal Transport - Top Construction Hazards - 1st Quarter 2006

    0 10 20 30 40 50 60 70 80 90 100

    Rails: Sub standard.

    Rails: Railswitch in poor condition.

    Walkways: Poor Housekeeping.

    Trackwork - Safety devices (T sprags / Fouling marks / Reflective c lothing / Toggle

    device)

    Water Control: Drains blocked.

    A B C

    O perational Control

    U nsafe A

    cts

    U nsafe C

    onditions

    System C

    ontrols

    R isk A

    ssessm ent

    Incident

    Threshold Lim it

    Loss

  • 26

    Derailments at Kopanang - 2006 YTD

    KOPANANG MINE - DERAILMENTS - 2006 YTD

    0

    5

    10

    15

    20

    25

    30

    35

    62 D

    W /

    62 D

    W 4

    62 KA

    T

    62 ST

    A

    62 S

    W 3

    64 AT

    T

    64 D

    W 2

    64 D

    W H

    64 KA

    T

    64 ST

    H

    64 S

    W 2

    68 /6

    2

    68 AT

    6

    68 D

    W B

    68 LE

    V

    68 ST

    A

    68 S

    W 1

    68 S

    W 1

    68 SW

    H

    70 AT

    K

    D ER

    A I