1

IAIN MENZIESHEAD OF ENGINEERINGAfrica 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

725

9 1231

20

76

26

148

3014

120

4126

5029

141

3241

1525 29

171

3241

1525 29

90

0

50

100

150

GN KOP MK MP SAV TL TT

Ris

k Va

lue

Q1 05 Q2 05 Q3 05 Q4 05 Q1 06

4

The Loss Causation Model

Operational C

ontrol

Unsafe A

cts

Unsafe C

onditions

System Controls

Risk A

ssessment

Incident

Threshold 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

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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

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Overall Thrust

• Long Term Action Plans

• Short Term Initiatives

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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

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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.

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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 2006YTD

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 06YTD

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

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Horizontal Transport Fatalities

82000

32001

72002

32003

12004

0220062005

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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 DerailmentsAnd Incedents

Do You Adhere To All Traffic Rules

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Engineering HT & VT Competition - 2005

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20

Horizontal Transport Audits

Horizontal Transport Audits100% done in 2005

020406080

100

TT MP SAV KP GN TL MK WWMineServ

MetVR

AGAAve

%

200520042003

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HT Risk Profiles (a)

Great Noligwa - W orkplace Risk Ratings Horizontal Transport

0

20

40

60

80

100

120

140

160

2003 2004 2005 2006YTD

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

2004 2005 2006

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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

Operational C

ontrol

Unsafe A

cts

Unsafe C

onditions

System C

ontrols

Risk A

ssessment

Incident

Threshold Limit

Loss

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

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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 communicationtechniques

Improper motivation

Physical capability

Inadequate/incorrect aptitude

Dressing Case Lost Time Serious

Operational C

ontrol

Unsafe A

cts

Unsafe C

onditions

System C

ontrols

Risk A

ssessment

Incident

Threshold Limit

Loss

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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

Operational Control

Unsafe A

cts

Unsafe C

onditions

System C

ontrols

Risk A

ssessment

Incident

Threshold Limit

Loss

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Derailments at Kopanang - 2006 YTD

KOPANANG MINE - DERAILMENTS - 2006 YTD

0

5

10

15

20

25

30

35

62D

W/

62D

W4

62KA

T

62ST

A

62S

W3

64AT

T

64D

W2

64D

WH

64KA

T

64ST

H

64S

W2

68/6

2

68AT

6

68D

WB

68LE

V

68ST

A

68S

W1

68S

W1

68SW

H

70AT

K

DER

AI

DW

2HL

TIP/

S

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Derailment Register - Kopanang

RAIL CONDITION4 FULL HOPPERS01:4020:30:0018:5064DW213X/C7249/01/2006

RAIL CONDITION1 FULL HOPPER03:005:00:0002:0064DW1/HLGE7239/01/2006

RAIL CONDITIONLOCO AND 2 HOPPERS01:2019:1517:5564DW2HLE72306/01/2006

LOCO 69500:2211:2211:0062DW/SWSPLIT6956/01/2006

RAIL CONDITION2 FULL HOPPERS01:234:15:0002:5264DW2HLGE7645/01/2006

RAIL CONDITION4 FULL HOPPERS00:1501:1000:5564DW2HLGE3805/01/2006

SWITCH CONDITIONLOCO 72301:0512:0511:0064DW2/16N7235/01/2006

SWITCH CONDITION2 FULL MAT. CARS00:1509:3009:1564SW2/214215/01/2006

1 HOPPER06:3006:3004:1109:2605:1564KATLEHOTIP4284/01/2006

RAIL CONDITIONLOCO 39201:1310:3809:2562SE3/HLGE3924/01/2006

SWITCH / RAIL CONDITIONRemarksNameTime

Arriv edTime

CalledTime Lost

Time Reraile

d

Time DerailedLev el / TipLoco

NoDate

Rigger called

De-Railments

28

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