Section 3 - Operating Environment: the operating environment for mobile equipment is satisfactory, hazards are identified and managed
This group of Business Inputs focuses on the operational management of mobile equipment covering:
- Standards, rules, and expectations for operating environment design and construction
- Work environment maintenance details covering- gradients, sheeting, drainage, lighting, signage, barriers, segregation, etc
- Work processes for managing changes in operating conditions
Review individual Business Input at comment level
> BI-03D.01 Road design guidelines set minimum standards for the construction and maintenance of the road network
Road design guidelines require that the development and maintenance of the physical operating environment adequately considers prevailing site conditions, the experience of mobile equipment operators (controllers) and equipment types/mix.
Manager Tech Services
Mine Design engineering guidelines ask and answer the key questions: If truck haulage is considered, are the ramps designed to accommodate truck haulage?; Can they be loaded and have adequate turning and dumping areas or are additional excavations required?; What distance must equipment travel for repairs and refuelling?; Is the loss of production opportunity less costly than the cost of establishing service and refuelling areas?; Can we use technological systems to identify the positions of vehicles?; How can we manage other hazards related to the deployed vehicles?
Site road design guidelines provide site specifications for:
- Grade (guidance based on type of equipment and activities occurring)
- Curvature (both horizontal and vertical)
- Line of sight (including orientation of U/G portals, break-aways/intersections, management of doors/ventilation screens and longer haul roads)
- Roadway and pavement widths
- Emergency stopping/run-off areas if required for long downhill sections of roadway
- Pavement shape
- Surface / pavement material
- Construction/mining of segregated roadways to separate HME and LVs as far as practicable
- Guideposts/delineators/roadway (hanging wall/backs) signage
- Parking areas size and delineation
- Fuel bays and batter charging locations (considering any introduced flammable liquids/gases)
- Stockpiles, accesses to bins and roadways around infrastructure
- Dumps
- Safety berms or windrows
- Dump geometry (including tip heads)
- Signs and barriers
- Lighting (area and traffic control)
Scheduled and damage response repair works are included in the required activities of the Development and Road Construction crew(s) on site – with appropriate equipment to maintain roadway pavements and provide best possible driving directions with consideration of prevailing conditions, dust sources and other factors which impact vehicle operator’s ability to safely operate.
Qn1: ramps are designed based on grade and width required for the largest vehicle using the ramp i.e. generally 1 in 10 ramp grade and width is 3.5 times width for two way ramp with top of ramp and curvature 4 times.
Qn2: working benches are based on turning radius of the trucks (generally 30 – 35m + maneuvering room + bunds and working area of other machines on the bench. Generally 50m is a minimum.
1 – distance for refuelling and repair – minor = no distance – fueling and tooling will come to it. Major repairs or maintenance = max 6km,
2 – site is too young to determine. Atlas has new gear. Production is two weeks on and one week off so the one week off is for all major maintenance and reduces risk of failures in production window.
3 – minestar is being installed in next 2-4 weeks. Currently using haulsmart. Presentation attached on timelines for technology roll out.
Road designs do consider factors above. Pavement design and materials for sub base is generally clay. Sand added occasionally for traction if wet weather.
Relevant Documents:
I attached relevant files below. Only one missing would be our mine design criteria sheet and principle hazard management plan for roads and operating areas.
Development and subsequent road construction and maintenance crews undertake required roadway construction and maintenance tasks – confirming that designs are delivered and maintained.
Road networks/excavations are constructed and maintained to meet designs.
Road designs are added to haulsmart which all personnel have access to. The designs are pegged and also loaded into GPS guided equipment (future state as minestar still pending). End of month surveys pick up and compliance to design is done on all mine designs – part of monthly KPIs which are discussed in quarterly mine plan meetings – mine plan attached.
- All mined openings are picked up by Survey to confirm alignment with design and/or identify non-conformances.
- Work area inspections confirm the conditions of roadways on a regular basis.
1 – As per above on survey confirmation.
2 – Pit inspections done daily by supervisor.
- WHSMR-Part 2 (4) (c) Roads PHMP to include design considerations for pavements, grades, and intersections
- WHSMR-Part 2 (4) (d) Roads PHMP should consider banks, steep drops, etc. near the road network
Action 1 – Check Road design criteria matches travelling speeds – Review the road design criteria to confirm that design matches operating speeds. Consider camber and corner arc radius.
Action 2 – Adverse weather preparation – Confirm process is in place at Atlas that will work as required e.g. adequate road drainage.
Action 3 – Mine road design and construction – Implement surveys that confirm road construction is to specification. Currently surveys are not being completed.
> BI-03D.03 Competent and site experienced water cart operators
Dust is well controlled without overwatering the road surface.
Mine Production Superintendent
Site performance requirements are in place for water cart operators so that dust is controlled without creating a slippery road. Performance requirements include:
- Spray application e.g. strip spraying
- Spray bar patterns and timing
- Water application based on speed
- Using an automated spray system
YIF water cart operations procedure, YIF water cart operations procedure sign off.
Trainers reinforce importance of watering and communication for water cart operators.
Via VOC process.
Assessment of water cart operator understanding of site requirements for dust management without compromising road surface conditions
Supervisors monitor dust control watering operations
By exception incident reporting.
As above.
Action 1 – Review SOPs for wet roads – Review SOPs for wet roads, consider road trains on clay roads and the road to Perseus.
Action 2 – Investigate the impact of rainwater on salt roads – Investigate the impact of rainwater and dust suppression on salt hardened roads.
> BI-03P.01 Road surface changes are identified and managed by vehicle operators
There is a site hazard management protocol detailing expected responses from vehicle operators when there are changes in road surfaces.
Mine Production Superintendent
Prepare site specific information for vehicle operators on identifying and managing road surface changes based on vehicle type covering:
- Weather variables such as rain, snow, ice
- Changes in road sheeting
- Over watering for dust control
- During road maintenance or construction
- Slips and debris (including responding to strata failure monitoring systems and observed conditions (surface and underground))
- Movement of work areas such as tip heads (movement of edge) and stockpiles (slip/slump of material being dug)
- Loading and unloading areas
- Initiating road maintenance activities (pavement and signage)
All operators are encouraged and ultimately told to drive to conditions.
Training and Assessment that vehicle operators can identify and manage changing road conditions and stability of surrounding excavations/infrastructure.
Vehicle operators alert supervisors to problems with the road network – which can initiate responsive road maintenance (in addition to planned maintenance activities).
Via prestart meetings , training, re-iterated at pre start meetings.
Supervisors or Superintendents respond to the identified hazard – implementing any required short and longer-term controls. After the hazard is brought under control, it is reported noting any additional controls.
As above.
> BI-03P.02 Lighting, delineation and signs are installed and maintained to standards that meet minimum site road design requirements
Site road design sets minimum standards for the installation, inspection and maintenance of lighting, delineation and signs that assist vehicle operators maintain situational awareness.
Mine Surveyor
Designs and construction requirements include standards for lighting of high traffic areas (e.g. around the mine infrastructure areas, vehicle (including remotely controlled) operating areas, dump edges, intersections, etc.) and signs to alert vehicle operators of road network requirements.
Survey mark out requirements for road network infrastructure to meet site requirements.
– Eastern Operations Design and Construction of Mine Roads Standard.
13. Intersections
13.2. Intersection Traffic Control
16. Delineation and Signage
20. LIGHTING POLLUTION
21. Audits and inspections of mine roads
Relevant Documents:
- Eastern Operations Design and Construction of Mine Roads Standard
Road construction crews place and maintain required permanent and temporary lighting, communication / information signage around the road network.
Roads should be built with pre-approved designs from the mine planners that meet all safety standards. Road designs are pegged by survey using the approved design and therefore should be built to spec. All survey set out is checked once complete. Any change to design needs to be re-approved before any changes made and survey re-pegs any changes.
- Survey regularly mark out and pick up locations of required elements of the surface and underground roadway networks – updating design and as-built plans as required.
Survey set out approved designs. No set out is carried out without an approved design from the mine planners. One the set out is complete, the work is communicated via email to everyone involved. Mid-month and end of month surveys along with specific surveys of requested areas are used to check as-built vs design.
Action 1 – Review and upgrade site signage – Review and upgrade site signage considering guidelines and the pit, maintenance workshop, approaches to intersections e.g. CR haul road and OB intersection.
> BI-03P.03 Expected routes by vehicle type are effectively communicated
All vehicle operators are aware of the routes that they are expected to travel on based on the vehicle type that they are operating e.g. segregated routes for light vehicles.
Mine Production Superintendent
There are multiple communication processes that provide expected route information to vehicle operators including:
- Preshift briefings
- Start of work roster traffic updates
- Maps
- Despatcher or supervisor advice
- Scheduling software
- Road signs
- Preshift briefings
- Start of work roster traffic updates
- Maps
- Despatcher or supervisor advice
- Scheduling software
- Road signs
- Pit permit VOC
Ongoing briefings and checks that vehicle operators understand the road network and how they are expected to operate i.e. where they are and the direction that are to travel.
- Preshift briefings
- Start of work roster traffic updates
- Maps
- Despatcher or supervisor advice
- Scheduling software
- Road signs
Supervisor and dispatch oversight.
Supervisors and peers monitor vehicle operator performance.
- Preshift briefings
- Start of work roster traffic updates
- Maps
- Despatcher or supervisor advice
- Scheduling software
- Road signs
- WHSMR – 014 (1) (r) Communication arrangements – between and within shifts to be included in SMS.
- WHSMR – 027 (a – 0d) Implement a formal process for communicating the state of the workings between shifts (with sign offs)
Action 1 – Improve new starter induction – Improve new starter inductions based on experiences of a 785 truck being driven on a light vehicle service road. Confirm that we are clearly communicating and reinforcing our operational expectations.
> BI-03P.04 Power line working distance management process
Safe working distances are always maintained between power lines and mobile equipment e.g. cranes, trucks, forklifts, etc.
Mine Planning Engineer
Procedures in place specifying minimum approach distances and required controls when working near and travelling under powerlines.
Warning devices required on power lines – Tiger Tails, Signage and Power Line Corridor entry permits.
Permit system which is rolled out in the rolling monthly training. Less than 3m is access permit, 3-10m is a vicinity permit. Power lines are bunded, underground in most instances.
Supervisors and mine planners are aware of minimum approach distances to power lines from mobile plant and expected controls e.g. use of permits in some circumstances.
Yes permit system.
Supervisors monitor activities of vehicle operators working around powerlines and confirm that they always meet site requirements.
Power corridors are designed, signed off and built to the design. Electrical engineer ensures compliance.
Action 1 – Review minimum heights to power lines under WHIMS – Review minimum heights to power lines under WHIMS, note the 7 m bucket can contact the overhead power line.
> BI-03P.05 Mobile equipment operators follow road rules and adjust based on conditions and circumstances
Mobile equipment operators follow road rules and adjust based on conditions and circumstances.
Mine Production Superintendent
Mobile equipment operators follow road rules and adjust based on conditions and circumstances by:
- Decreasing speed
- Increasing clearance distances
- Stopping if required
- Notifying hazards
As previous question where operators are trained to drive to conditions.
Relevent Documents:
VOC process, adherence to YIF procedures.
Ongoing briefings and checks that confirm that mobile equipment operators understand road rules and are aware of necessary operating adjustments based on conditions and circumstances.
VOC process, adherence to YIF procedures.
Supervisor and despatch oversight.
Supervisors and peers monitor vehicle operator performance.
VOC process, adherence to YIF procedures.
WHSMR-Part 2 (4) (a) Roads PHMP to consider mobile plant characteristics and impacts on driving
WHSMR-Part 2 (4) (b) Roads PHMP to consider environmental conditions that could impact driving
> BI-03P.11 Clear requirements for loading of trucks by digger/loader
Loading mobile equipment is safe and productive.
Mine Planning Superintendent
The loading system must prevent the cabin from loads that exceeds the maximum weight impact to protect the operator.
Operational and safety requirements are specified in procedures and other documents and media e.g. instructional videos. They provide information to the operator about:
- Vehicle access
- Vehicle loading
- Vehicle exit
- Leaving the vehicle during loading
- Emergency response
They include relevant change management thresholds such as:
- Changes in vehicle type
New operators.
Engineering sign off that the loading system and the vehicle in use meet are fit for use.
Vehicle operators are trained and assessed in loading requirements including emergency response.
Supervisors monitor activities of vehicle operators loading from fixed structures confirming their activities meet site requirements.
Action 1 – Carry out situational awareness training for truck loading – Carry out situational awareness training for truck loading by diggers. Investigate the opportunity to provide better situational awareness and leadership for excavator and dozer operators.
> BI-03S.05 Infrastructure protection – placement of barriers and/or warning devices to prevent unwanted vehicle interactions
Site infrastructure is protected from unplanned contact with mobile equipment.
Fixed Plant Engineer
When constructing roads near infrastructure, hazardous locations or work areas the documented requirements include placing windrows, bunds or physical barriers (designed to reduce injury threats if struck (i.e. rounded and/or frangible)) – and where these cannot be placed (e.g. for overhead lines) then warning devices (over height alarms, cable balls, geo fencing etc.), or vision enhancing components (mirrors, translucent ventilation curtains etc.) are installed.
Information is prepared on requirements and workers are trained in how to implement and adjust protection barriers/warning devices.
Barriers and warning devices that protect site infrastructure from contact with mobile equipment are installed as designed.
Protection types include physical barriers that prevent contact through to warning/vision enhancing devices to enhance vehicle operator’s situational awareness.
Workers only remove or modify barriers in line with instructions/site requirements.
As designed, installation of barriers and warning devices is confirmed. Regular inspections and tests confirm performance requirements are being maintained.
Action 1 – Review roller door heights at the mine workshop – Review roller door heights at the mine workshop and post height restriction information.
> BI-03S.20 Speed and other operating parameter data send
Equipment operating data (speed, travel paths, engine performance/load, etc.) is captured and sent for monitoring and analysis.
Engineering Manager
Equipment operating data is captured and sent for monitoring and analysis.
Not currently installed, system still being profiled and installed by OEM.
- WHSMR-Part 2 (4) (e) Roads PHMP should consider speeds, volume and different vehicle types
> BI-03T.01 Ceasing Operations Procedure – compromised operating environment
Sites should have cease operations processes (Trigger Action Response Processes/Plans) in place for situations for when it is no longer safe to continue normal operations using mobile equipment.
Manager Mining/Operations
Procedures in place for compromised operating conditions
Develop and implement a process to cease operations in situations where it is no longer safe to operate mobile equipment:
- Failure of roadways e.g. slumps, washouts, sink holes
- Actual or potential geotechnical failures
- Fires and smoke
- Floods
- Precipitation: snow, sleet, rain, hail etc.
- Dust
- Temperature extremes
- Infrastructure potential or actual failure
- Potentially explosive(e.g. methane rich) atmospheres
- Falls of ground
- Seismic events
- Loss of ventilation
- Animals etc.
Training and assessment in requirements for vehicle operators, supervisors and management.
Supervisors monitor activities of vehicle operators – confirming their activities meet site requirements.
WHSMA 30 – Industry SHR can direct a suspensions of activities
WHSMR – 057 Implement TARPs and Engineering responses for out of specification ventilating air
Action 1 – Ceasing work triggers – Develop triggers for actions to assess if work should cease. Formalise the experience of knowledgeable personnel.
Action 2 – Stopping the job – Confirm that personnel working at Atlas are aware of the process to stop the job if required. Provide clear messaging and support so they are confident and empowered to stop the job. Illustrate processes using real and defined triggers.
> BI-03T.05 Lightning and Extreme Weather TARP
Sites should have procedures and associated training resources (Trigger Action Response Processes/Plans) in place for heavy rain and storm situations that increase the potential for unsafe road conditions and/or lightning strike on mobile equipment.
Manager Mining/Operations
Procedures in place for storm situations and other weather impacts on road / mobile equipment operations.
Develop and implement a process to minimise potential for fire from lightning strikes and other weather impacts.
- Monitor lightning activity using meteorological forecasts and other early warning detection systems
- Lightning protection or diversion systems should be installed in accordance with appropriate standards (e.g. National Fire Protection Agency 780 2011 Standard for Installation of Lightning Protection Systems; AS/NZS 1768 2007 Lightning Protection)
- Provide timely communications to allow sufficient time for all exposed site personnel to seek appropriate safe shelter
- Place equipment in protected area away from fuel sources (i. stop damage; ii. Stop spread to fleet)
- Instigate awareness training for workers that highlights the risks of lightning strikes and other exposure to weather related impacts (slippery roads, etc.)
- Develop a trigger action response plan (TARP) for lightning and electrical storms that outlines responses to a storm at certain distances away from the mine (e.g. a staged response depending on distance)
Procedure for the use and protection of explosives in known lightning conditions.
Training and assessment in requirements for Vehicle Operators during storms and other weather conditions impacting road network safety.
Supervisors monitor activities of Vehicle Operators during storms – confirming their activities meet site requirements.
WHSMR – 032 (2)(i) Provide an earth system adequate to protect against touch potential, lightning and energisation of explosives
WHSMR-S2(3)(3)(f) Electrical Engineering CP should consider lightning strike potential
> BI-03T.10 TARPs prepared for unwanted conditions
Trigger action response plans (TARPs) are put in place for conditions which will impact on the site’s ability to achieve safe movement of mobile equipment.
Manager Mining/Operations
Subjects covered should include those which impact the road network, such as: electrical storms; high winds/raised dust; reduced visibility (e.g. loss of area lighting); road pavement conditions (wet, damaged, etc.); compromised access controls, etc.
Also conditions which compromise road traffic levels such as: reduced number accesses to working areas; short term work plans that lead to increased vehicle movements; external traffic movements (e.g. from a neighbouring operation), etc.
The developed Trigger Action Response Plan should have gradated levels and required responses such as:
- Green Level. Threat is not present and/or is well managed using routine processes and machinery.
- Yellow Level (optional). Threat is present but not to an extent that is hazardous. This level is addressed by increased vigilance and communication.
- Amber Level. Threat level has increased and can be managed through changes to processes and heightened vigilance of workers and supervisors.
- Red Level. Threat is continuing to increase and workers (apart from any deployed to reduce the threat) are withdrawn to safe locations.
Supervisors and workers are trained in developed TARPs and their competence is confirmed.
Conditions beyond those expected trigger an appropriate response from sites escalating awareness and ceasing operations as appropriate. More significant (Amber and above) triggers are communicated to more senior personnel on site.
- TARP levels and site responses are regularly reviewed by senior manager.
Amber and Red responses and levels are communicated with external parties as required.
WHSMR – 057 Implement TARPs and Engineering responses for out of specification ventilating air
Action 1 – Confirm the range of TARPS – Confirm the range of current TARPS that we have now and review which are needed. Be prepared to remove tarps and confirm that they are aligned with the safety management systems.
Action 2 – Review and consolidate site TARPs – Review and consolidate site Trigger Action Response Plans for unwanted conditions. Note there is uncertainty about what TARPs are in place, how they are rolled out, and if we have all that we need.