TRANSPORT SAFETY. BUSINESS SWEDEN THE SWEDISH TRADE & INVEST COUNCIL 26 September 2013 UNCLASSIFIED

Transcription

1 TRANSPORT SAFETY BUSINESS SWEDEN THE SWEDISH TRADE & INVEST COUNCIL 26 September 2013

2 RP 35 - MANAGING RISK OF EQUIPMENT PLANT PERSONNEL INTERACTIONS IN MINING OPERATIONS Gareth Williams Head of Safety, Anglo American Plc

3 OUTLINE Overview of Anglo American Challenges in managing transportation risk RP 35 Process RP 35 Stakeholders Interaction Risk Profile Reducing Interaction Risks Risk Reduction Streams (1..3) Current / Planned Systems Journey Map External Groups

4 OVERVIEW OF ANGLO AMERICAN Our vision is to be the leading global mining company, by being the investment, the partner and the employer of choice by; Portfolio of world class assets Organising efficiently and effectively Operating safely, sustainably and responsibly Employing the best people One of the world s largest mining companies. Focused on operating world class assets in the most attractive commodities: Iron Ore and Manganese Metallurgical coal Thermal coal Copper Nickel Platinum Diamonds Over 145,000 permanent employees and contractors Operations in Africa, Asia, Australia and North and South America 4

5 CHALLENGE ON MANAGING TRANSPORTATION RISK The reality High Potential Incident (HPI s) evidence shows that equipment collisions are a real risk Collision avoidance technology as presently deployed is not adequately effective The Group requirement Integrated collision avoidance and collision mitigation on SME s are required for both present and future fleets Collision mitigation : when the collision does occur the consequences are controlled and reduced For haul trucks by eg : integrated light/heavy bumpers cab location/configuration active collision avoidance systems integrated into operator controls 5

6 NON-COMPETITIVE COLLABORATION RP 35 is the Recommended Practice (RP) for selection and assessment of collision avoidance systems for the Anglo American Group RP 35 in a nutshell Understand and refine the high risk scenarios Develop requirements for each scenario Analyse gaps in current or new collision avoidance systems Identify and implement improvements with technology partners Taking RP 35 to industry CRC Mining - Australia ISO and RSA DMR (MOSH) Australia NSW/QLD (MEPIAG) OEMs & other mining companies 6

7 FOUR STEPS... 1 High Establish underlying baseline risk for all scenarios using HPI s and industry registers 4 Classes of Controls and Treatments (Preventative & Corrective) 2 Significant Identify other controls (such as separation of traffic) and apply these first 5 Types of Collision Avoidance Systems 3 Medium Assess effectiveness of existing Collision Avoidance System Controls and Treatments 66 Classifications of Scenario and Site Requirements 4 Low Analyse gaps in current Collision Avoidance Systems and implement improvements RP Categories to define characteristics of Collision Avoidance Systems Risk Level 1 ZTC 2 SAT 3 PAT 4 PDT 5 CAT Zone Control Technology for managing objects entering, leaving or within a zone Safety Adherence Technology for managing behaviour of objects within a zone Proximity Awareness Technology to assist an operator to see nearby objects Proximity Detection Technology to automatically detect the presence of nearby objects Collision Avoidance Technology to actively prevent collisions between objects 7

8 RP 35 PROCESS Understand and refine the High Risk Scenarios Identify and implement improvements with Technology Partners Zero Harm Develop Requirements for each Scenario Analyse Gaps in current or new Collision Avoidance Systems 8

9 Controls & Treatments APPLYING RP 35 Process Flows Process Deviations WRAC Baseline / Now Risk Exposure Risk Reduction Realised Equipment Activities Other New Risk Exposure Now Identify Critical Controls New Assess Control Effectiveness Requirements Measure / Audit Performance 9

10 RP 35 STAKEHOLDER ROLES Responsible Assists* Consulted Informed Identify interactions with significant risk Group BU Vendor A R - Complete interaction risk matrix Prepare site requirements from RP 35 classifications A R - A R - Assess capability of now/new technology Highlight gaps between requirements and capability I R C I R C Identify critical controls & evaluate effectiveness / measure-audit *Modified RACI clarifies Accountable-Responsible role differences A R C 10

11 INTERACTION RISK PROFILE Business Unit RP 35 Interaction Matrices Iron Ore - Kumba Iron Ore - Brazil Surface Metallurgical Coal UG Copper Surface Thermal Coal Anglo American Group UG Nickel Surface Platinum UG Niobium Surface DeBeers Phosphate UG 11

12 REDUCING INTERACTION RISK New / Next Technologies RP 35 Future Needs Group Tolerable Risk Profile - Interactions Operational Risk Management Roadmap Alignment Support Services Automation (Stream 3) Technology Innovation Business Unit Control (Stream 2) OEM Equipment Active OTM Community (incl. OEMs) Now Technology Selection & Implementation Assist (Stream 1) Machine Interfaces 2020 Requirements 12

13 STREAM 1 - ASSIST Provides assistance to operator of equipment Supplements Other controls and treatments to manage risk Many OTM After Market solutions fitted to mobile equipment Focus on soft Separation controls : Video-Visual-Voice-Audio alarms Use of limited signal / data inputs from machine Control of machine via human operator only Heavy reliance on administrative procedures to manage risk Challenging to provide two Very Effective controls to mitigate risks in every scenario with elevated risk levels 13

14 STREAM 2 CONTROL OTM After Market solutions in development / early stage deployment Focus on hard Engineering controls to interlock machine OEM position on exposing machine controls: Underground : Reluctantly working with OTMs Surface : Major OEMs are resisting, especially with mobile equipment Primary interface to control machine is still via human operator Interlocks engage only in specific circumstances Reduces risk in specific scenarios Regulatory environment changing towards enforcing minimum levels of control as a mandatory requirement Careful assessment of risk is crucial in decision to deploy / not-deploy 14

15 STREAM 3 - AUTOMATION Major OEMs offering closed systems on limited range of equipment Aftermarket OTM solutions emerging (mostly without OEM assistance) Human operator supervises only (no direct control) Risk profile dramatically lowered when full automation is cost effective Semi-automation offers reduction in risk for specific cases, e.g. Auto-steer on haul road incline / decline (e.g. following pantograph) Auto-drill May only be applied to a limited part of the mobile equipment fleet where the business case is favorable OEM closed systems may not be suitable for many site / operations with mixed fleets Control interfaces (Stream 2) are critical to stimulate development of solutions 15

16 INTERACTION RISK REDUCTION Business Unit (BU) Surface Underground U Business unit 1 - Business unit 2 C D U D Business unit 3 Business unit 4 U N Business unit 5 U P D Business unit etc Business unit etc Business unit etc Business unit etc Business unit etc U : Upgrade planned / in progress N : New system planned / in progress C : Currently being implemented D : In Development / Trials 16

17 JOURNEY MAP Phase 1 (to Dec 2013) Phase 2 ( ) Phase 3 ( ) RP 35 Review (across BUs) Interaction Matrix Gap Analysis Control Effectiveness Define target equipment based on risk profile and no.s of equipment (groupwide) Specific projects aimed at reducing interaction risks across AA group RP 35 OEM Engagement Operational Risk Profile Control Interfaces Agree Way Forward Specify 2020 objectives for all target equipment Assist / Control / Automation Streams Validation of performance RP 35 Industry Engagement What s required? Who s interested? What participation? OEM control interfaces defined and scoped for future equipment purchases Control interfaces implemented for all major OEM equipment RP 35 Support Services in place across Anglo American Group Update of RP 35 Initial equipment arriving with control interfaces in place / initial systems Risk reduction realised for all new equipment arriving on-site 17

18 EXTERNAL GROUPS UGM Safety ISO IEC Standards South Africa DMR (MOSH) AS Australia NSW/QLD (MEPIAG) Industry Forums Leader Groups Peak Bodies Long Term SANS Regulatory South America Chile Brazil Peru OEM Engagement Targeted Projects Medium Term Industry USA MSHA Conferences Expos Lead / Influence 18

19 RESOURCES Under direction of Transportation Safety Risk Improvement Group: Project Coordination Industry Group Representation CEO level Delegate level (e.g. Engineering Council) Expert/practitioner level M&T Engineering Group Technical Standards (incl. update of RP 35) ISO / IEC Standards Development OEM Engagement S&SD Operational Risk Management Risk & Assurance M&T Technology Development Automation Streams RP 35 BU/Site Support RP 35 Training 19

20 CONCLUDING REMARKS Interaction Risk is a significant contributor to Anglo American risk exposure We are using RP 35 to identify key risk areas and to implement suitable controls for now and future in a risk driven approach Ultimate objective is for equipment to suitably equipped when it arrives on Anglo American sites Expect that more standard types of Collision Management System controls will become standard on most OEM equipment (e.g. camera, radar where applicable) with simple interfaces initially Industry engagement is critical and we are seeking the right support that will foster development of standards SECURITY CLASSIFICATION 20

21 THANK YOU