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HSE EC Con nferrenc ce 2012 2 2 end dium m off Compe N Nom mina ation ns 2009 9 2010 0 2012 2


2009 9 No omiinattion ns


HSEC C CONFERENCE 20012

A AIRLY Y–E ENVIIRON NME ENT Exc cellence and d Innovation ns Data Title

Biod diesel Trials

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

ote the use of o biodiesel inn the mining and In orrder to promo consstruction indu ustry, Airly Coal determinned that its consstruction prog gram would utilise biodieesel. The tria als are desig gned to dem monstrate that biodiesel iss a viable alte ernative to m mineral diesel which will greatly assist in reductions of gree enhouse gas emissions. Ultimately, itt is Airly Coa al’s inten ntion to use biodiesel b in itts undergrouund mining fleet. esel was included as a K Key Performa ance The use of biodie c with Laing O’Rouurke. Suppo ort from Indiccator in the contract the ssupplier National Biofuels s Group wass also soughtt to assisst with educa ation of the many m subconntractors and d equi pment opera ators on site. Therre are curren ntly no provis sions with deevelopment apprrovals, EPA licensing or other o governnment require ements for th he use of bio odiesel. There is also so me resistanc ce to the use of biodiesel due to unkno own ramificaations on equ uipment. Thiss resistance, particularly with w earthmooving contrac ctors has been a key reason r that has h hampereed the use off biod iesel in the mining m and construction iindustry. Ce entennial Airlyy decided to use u its consttruction progrram to dispe el the myth hs around the use of biod diesel and ulttimately show w case the m mine to the rest r of the mining industryy. esel has bee en integratedd into the The use of biodie ntract as a KP PI with financcial benefits consstruction con attacched. Cente ennial Airly ha as also usedd biodiesel in its site vehi cles and on site generato or. Althoughh in use for only three e months, bio odiesel has been b integraated into the majority of th he constructio on fleet. Cen ntennial Airlyy has assiste ed the conttractor with data d and educational matterial on the envi ronmental be enefits of usiing biodiesell. National Biofuels B ctive in talkin ng to contracctors and worrking has also been ac throu ugh issues as a they have arisen. ut some setbbacks but the ese are The trial has not been withou bein g actively resolved. The benefits of tthe projects success be significant in reducing green housee gas emissions will b with the ultimate goal of repla acing all min eral diesel usage for th he ongoing operation o with 100% bioddiesel. It is has h yet to be e adopted by y other mining operationss but once ac ccepted and long term be enefits are kn nown, it will bbe easily transsferable with hin the mining g industry.

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HSEC C CONFERENCE 20012

AN NGU US PL LACE - ENVI E RON NMENT Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Exc cellence and d Innovation ns Data Angu us Place Haul Road – no oise modelingg and inspec ction proto ocol nking Angus Place to Waallerawang Power The haul road lin n identified th hrough quartterly monitoriing as Statiion has been a sig gnificant conttributor to the e Colliery’s ooverall noise emisssions. Many factors are e considered to influence such resu ults, such as the number and timing oof truck move ements, truckk type, the prroximity of re eceptors, roaad surface type and the rroad’s structu ural condition n etc. The problem was s assessed by b modeling the haul roa ad using Soun ndPLAN nois se modeling software. A 3D digital te errain map p depicting all relevant top pographic infformation wa as inpu tted into the model. In addition, prevviously collec cted nois e logger data a, ground typ pe, shielding and atmosp pheric data a was include ed in the mod del. In ad ddition to the e noise mode el a Haul Roaad Inspection n Proto tocol was dev veloped, to id dentify haul rroad deformations (e.g.. potholes, co orrugations) that can be prioritised fo or main ntenance. Poor road con nditions can llead to eleva ated nois e results. The risk associated with this problem is tthe potential for Enviironmental Protection P Lic cense exceeddences to oc ccur, resu ulting in poten ntial fines being issued aand/or prosec cution.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

ate high leve els of due diliigence and In orrder to facilita conttinual improv vement in env vironmental managemen nt, as well as reduce th he likelihood of license noon-compliances, a w proposed d to enable ppreventative actions zoni ng system was to be e prioritized accordingly. a Noise modeeling has ena abled high and low prio ority zones to o be establisshed along th he haul d based on exceedence likelihood. R Road deforma ation road type es have been n risk assessed to develoop a priority system s base ed on conseq quence seve erity. This haas been facto ored into the Inspectio on Protocol.

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HSEC C CONFERENCE 20012

How th he solution goes g beyond complian nce

Resu ults from the e SoundPLAN N computer nnoise model have aide ed the evalua ation of the proposed tendder agreeme ent, rega arding contra actor trucks proposed p for use at Angus Placce. Modeling g will enable the trial of suuch trucks ag gainst the E EPL criteria prior p to their introduction.. Such invesstigations su urpass curren nt monitoringg requiremen nts and high light diligent planning. Furthermore, the trial of new truckks will enable e the introduction of a moodified contra act with envi ronmental crriteria and ex xceedence ppenalties esta ablished. The developed in nspection protocol highligghts the due dilige ence and pro oactive appro oach adopteed by Angus Place, rega arding the op peration of the haul road aand determin nation to co omply with no oise limits.

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

en the long te erm nature of the haul roaad (life of mine) Give and its proximity to the towns ship of Lidsd ale the conssequences associated a wiith potential nnoise criteria a exce eedences are e considerab ble. Such moodeling may enable the d developmentt of noise mittigation optioons, such as the consstruction of noise n bunds along a high rissk sections of o the haul road or app plication of ad dditional noisse suppressa ants on truckks. Such sollutions requirre a fully inteegrated approach from m the environmental monitoring to the managemen nt of load ing plants an nd coal distribution. s considerable applicabiliity across a diverse d Thiss solution has ge of industries. Essentia ally, any induustry which rang operrates a noise e constrained d haul road ccould benefit from nois e modeling and a the imple ementation oof associated d noise mitig gation strateg gies. Speccifically in terms of mining, any open cut operation regu ulated by nois se exceeden nce criteria coould utilise mod deling to dete ermine high risk r areas. R Relevant mitigation strattegies (inspe ections in the case of Anggus Place) ca an then be im mplemented to reduce ris sk likelihood.. Such mode eling is also applicable to o blasting, in n terms of deepicting the angle a of on. This is hiighly valuabl e to those nois e propagatio h are in close e proximity too residents. operrations which As d demonstrated d by Angus Place, P the usse of noise mod deling is highly applicable e to undergroound operatio ons (note e the environ nmental business plan reequirement to o unde ertake a site noise model during 20099/10) not only for asse essing road haulage h but any a high riskk area or activity such h as explorattion, exhaustt fans, heavyy plant etc.

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HSEC C CONFERENCE 20012

A ANGU US PLAC P CE – HEA ALTH H AN ND SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data Beltt Structure Cassette es

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

w members in panel experiencing d difficulties in i Crew unlo oading & lay ying out beltt structure. Res ulting in back sprains & strains plu us delays in n com mpleting beltt moves.

dinator asse essed probleems and de esigned Log istics Coord uck bill to su uit conveyorr cassettes mitigating risks r a du iden ntified. Exce eeds compliance requirements. Beltt structured delivered in n packages but were no ot user frien ndly for panel personne el. Mod difications have h improved this

Systtem introduced in February 2008. Prov ven to be ve ery successful. No rreported inju uries or inciidents recorrded throug gh Ang gus Place AI/II system. The system is now n used as s normal praactice on deve elopment be elt moves

er Centennial sites have shown intterest in con ncept. Othe Therre are otherr similar sys stems but th his design is s site spec cific and implemented through t con nsultation with w emp ployees on site s offering benefit of i nvolvementt and own nership of prroject.

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HSEC C CONFERENCE 20012

Innovation title:

Cente enniall Awab ba Easy Cable Hang ging Operati on

““ECH HO”

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HSEC C CONFERENCE 20012

ed Problem:: who identifiied the probllem, how the e problem wa as assessed, what was th he identified Identifie risk asso ociated with the problem

TEP CHANG E program th he Awaba wo orkforce deteermined thatt the risks of In 2009 following on from the ST om conventio onal cable ha andling when n tying cables to the roof was contribuuting to a large proportion n injury fro of long tterm neck, sh houlder and back strain in e workforce determined d thhat the conve entional rope e njuries. The es used were e not being used correctlyy, which mad de them to ha ard to removve. The proc cess in most cable tie occasion ns also requiired the use of a Eimco, Q QDS man ba asket and thrree operatorss and was an n awkward process causing und due stresses on employe ees hands as s they tied up p the cables. ba has a limiited and olde er workforce, an idea was s needed tha at reduced thhe stress on the t physical As Awab person, reducing the e overall dem mands on peo ople and machinery availlability, whilsst allowing for quick installatiion and remo oval of cables. Without a solution to this t problem the limited aand aging wo orkforce will continue e to be injure ed and impac ct on the “Ste ep Change� focus f to redu uce injury.

Image 1 1.0 showing the conven ntional cable e hanger me ethod.

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HSEC C CONFERENCE 20012

Solution n: how the solution came e about, how w the solution n mitigated th he risk

arly 2009/2010 financial year y followin ng on from the “Step Change” program m an employ yee put In the ea on to the cab forward an idea to hiis team mate es of a solutio ble hanging problem. p Foollowing on frrom positive ement team encourageme e ent and conssultation with h the HSEC Comittee, C thee Awaba worrkforce came e manage up with tthe Easy Ca able Hanging g Operation n - “ ECHO”.

The eassy cable hang ger is a simp ple solution to o a common problem in all a undergrouund mining environmentss. That is, it eliminated d the need fo or a cable ha and to raise an a awkward and a heavy caable above shoulder s height, w whilst tying itt up (for a len ngthy period of time). The e easy cable hanger enfoorces; 

a more ergo onomically friendly stance e when installling and rem moving cabless,

reduces ove er exertion fro om the stresss and strain of holding a cable whilst tying with an n awkward cable tie,

move, and is simple to use and rem

e effective th han cable tie es. is more time

Is suitable fo or 35mm and d 25mm cabl es.

Image 2 2.0 showing the Easy Cable Hangerr and applic cator.

d Complianc ce: How the solution s goess beyond com mpliance Beyond

goes beyond compliance by eliminatiing the risk of o a cable ha and operator straining the eir back, ECHO g shoulder, neck and other o muscle es. It remove s possible in njuries from pinch p points aand potentia al cable e from consta ant twisting movement. m damage

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HSEC C CONFERENCE 20012

The eassy cable hang ger is totally re-usable an nd removes the use of cu umbersome tangled cablle ties that are left in the goaf an nd made from m non renew wable materia als. These ca able ties havve known to end e up ollers leading g to expensivve down time e. tangled up on belt ro ger frees up Awaba’s eim mco availability in most sc cenarios as w well as remo oves the The eassy cable hang situation n where cable e hands are hunching ovver in a platfo orm against the t roof whenn working ou ut of a QDS elevated d basket or la adder. ECHO is s a group in nvention, 100% designe ed and drive en by the wo orkforce to rreduce injurry, environmental and electrical damages, d alll of which le ed to a reduc ction in opeerating costs s.

Image 3 3.0 shows ECHO (cable hanger and d applicator) in use.

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HSEC C CONFERENCE 20012

Integrattion: How the solution is integrated in nto the busin ness

As the in nnovation is still relatively y new it is ru nning throug gh the final te esting stage aand will be in n full use, supplem menting the conventional c 9. Final imple ementation w will be preceded by a riskk cable ties in August 2009 assessm ment and sub bsequently a Safe Work M Method State ement. The SWMS S will bbe written and d developed by the A Awaba workfo orce who willl present the e item at a Prre Shift Briefing to those m members of the workforcce not involve ed with the fe easibility and d design stag ges.

posed integrration into ou ur normal ope erations will follow f the 10 0 hurdle apprroach with 10 00% The prop workforrce impleme entation. 1. We had con nsultation with Awaba em mployees an nd OHS Com mmittee. w a presen ntation was d delivered to all a shifts abou ut the cable hhanger and documented d 2. Hazard ID with the feedbac ck. d new system ms. 3. Risk Assess the old and eveloped from m the outcom mes of the Riisk Assessment. 4. A SWMS de o before an nd after implementation. 5. Training willl be carried out n carried outt by Deputiess after implem mentation. 6. Supervision d in the weekkly planned task t observation on the uuse of the hanger. 7. Monitoring is scheduled y review will be carried o out after impllementation. 8. A 3 monthly M Audit will in nclude the ha anger - The results will be tabled at thhe weekly management m 9. Weekly U/M meeting on – Changes s made follow wing feedback and change managem ment plan 10. Rectificatio

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HSEC C CONFERENCE 20012

Benefit:: how could other o sites (o or industry) b benefit from the t solution, has it been aadopted else ewhere?

The tran nsferability accross the Ce entennial Coa al Group and d other industry workers iis easily achiievable as alll mines usse cables (siimilar to Awa aba).

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HSEC C CONFERENCE 20012

Innovation title:

Cente enniall Awab ba Vacuu V um Dru um Liffter

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HSEC C CONFERENCE 20012

Identifie ed Problem:: who identifiied the probllem, how the e problem wa as assessed, what was th he identified risk asso ociated with the problem

kforce develo oped and imp plemented a 20 litre oil drrum cassette e pod as an In 2008 The Awaba colliery work onal, environm mental and safety s improvvement. The aim of the pod p was to reeduce inciden nts and injuryy operatio from workers lifting 20 2 litre oil dru ums out of co onventional oil o drum pods. Since impplementation wide mentary reco ognition have e been receivved including g the people’s choice awaard from the 2009 NSW complem Mineralss Council OH H&S Conference. Howeve er, since ince eption it was identified byy the Awaba Colliery HSEC ccommittee tha at the 20 litre e oil drum ca assette requirred filling and d emptying. T This action required r e movementt of picking up the drums from oil pallets and trans sferring them m to the cass sette. It was repetitive this movvement that was w identified d as a possib ble point for a stress or strain s injury aand as such required r a new load ding method.

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HSEC C CONFERENCE 20012

Solution n: how the solution came e about, how w the solution n mitigated th he risk

Followin ng identification of the pro oblem by the e HSEC comm mittee a rese earcher was coordinated to investiga ate the issue e and a possible way to e eliminate or reduce the de etrimental ouutcome. Followin ng on from many m weeks of o research a and consultattion with the HSEC comm mittee and workforce w the recomm mendation for the use of an a air operate ed drum lifterr was agreed d upon for fu rther researc ch. etermined th he drum lifter; It was de 

removes the e need for an ny physical sttrength in the e loading,

removes the e twisting stre ess and straiin on the bod dy when load ding the drum ms into the ca assette by hand,

is quick and easy to use,

e need for a fork f lift, and removes the

eliminates th he possibility y of drum dam mage whilst loading.

Image 2 2.0 showing the t Vacuum drum lifter.

d Complianc ce: How the solution s goess beyond com mpliance Beyond

operated dru um lifter goes s beyond com mpliance by proving the current c systeem in the Aw waba Colliery The air o has the ability to con ntinually imprrove the systtem. In this situation s it ha as done so byy using risk managemen m t es and engin neering soluttions (using ttechnology) to t prevent po otential incideents and inju uries. processe

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HSEC C CONFERENCE 20012

The air o operated dru um lifter (as shown s in ima age 3.0) goes s beyond com mpliance by allowing full use and thus the bene efits of the 20 0L oil drum cassette c inclu uding; •

Elimination/rreduction of potential stra ain and strain n injuries

Elimination of o full drum damage d durin ng loading and transportiing

Elimination of o the need for f a fork lift tto load and unload u

Elimination of o spills from oil drum dam mages as we ell as catchm ment of the drrips from use ed oils drumss to return to surface s for re ecycling.

The air operrated drum liffter is modifia able to be us sed on other similar liftingg applications of greater or less weights.

mplementatio on of the oil drum d cassette e at Centenn nial’s Awaba Colliery therre have been n nil oil drum m Since im related ssprain/strain injuries or sp pillage dama age incidents s reported.

ge 3.0 showing the Vacu uum drum lifter in use on a 20 litre oil drum. Imag

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HSEC C CONFERENCE 20012

Integrattion: How the solution is integrated in nto the busin ness

The air o operated dru um lifter was a straight forrward integra ation into full operation. T The air opera ated drum lifter rep placed the co onventional drum d handling g techniques s when loading the 20 litrre oil drum ca assette and thus elim minated drum m handling re elated damag ge and injury y with nil incid dents or injurries reported d to date.

posed integrration into ou ur normal ope erations follo owed the 10 hurdle h approoach with 100 0% The prop workforrce impleme entation. 11. The HSEC committee c ha ad consultattion with the e Awaba workforce. 12. Hazard ID with w a presen ntation was d delivered to all a shifts abou ut the air opeerated drum lifter and the e feedback was w documented. 13. The air operrated drum liffter was Risk k Assessed and comparred against tthe old system. 14. A Safe Work Method Sttatement wa as developed d from the ou utcomes of thhe Risk Asse essment. 15. Training on the air operated drum liffter was carried out beforre and after i mplementatiion. n was conducted by the H HSEC comm mittee after im mplementatioon. 16. Supervision eekly planned task observation on thee use of the lifter. 17. Monitoring was scheduled in the we y review was s carried outt after implem mentation and returned nnil issues. 18. A 3 monthly EC coordinattor Audit inclluded the lifte er with the re esults tabled at the week kly 19. Weekly HSE managemen nt meeting on – Changes s made follow wing feedback and change managem ment plan as required. 20. Rectificatio

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HSEC C CONFERENCE 20012

Benefit:: how could other o sites (o or industry) b benefit from the t solution, has it been aadopted else ewhere?

Represe entatives of a number of other o Centen nnial mines using u MPV trransporters hhave reviewe ed the operatio on of the 20 liitre oil drum cassette und derground att Awaba and intend to haave cassettes s manufacctured for the eir site opera ations. As succh it is recom mmended tha at as a solutiion to a potential problem m as highliighted by the e Awaba HSE EC committe ee, could be the use of th he air operateed easy drum m lifter.

Although h intended fo or use with th he 20l oil dru um cassette the t air operated drum lifteer is modifiab ble to be used on many other similar lifting g application of greater or less weightts across all industries an nd is a ble piece of technology t u used to solve e a common problem. p commerrcially availab

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HSEC C CONFERENCE 20012

A ABA - COMMU AWA UNIT TY Field Nam me Title

Exc cellence and d Innovation ns Data Awa aba Colliery Community C and a Environm mental Initiative

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Awa aba Colliery y views the local coommunity as a key stakkeholders in n the com mpany and aim to develop d partn nerships and improve its engagem ment with th he local com mmunity.

Awa aba Colliery approached d the local primary school to uss the pos discu ssibility of su upporting a school proje ect with heal th or enviro onmental be enefits. Thee school req quested assisstance to cre eate a school garden. Supp porting the lo ocal commun nity is not a l icence requirement of th he mine.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

ool gardens are a great way w to encouurage studen nts to Scho emb brace both he ealth and env vironmental iideals. This is i done throu ugh learning of the biolog gical processses that are invo lved in garde ening, including environm mental benefits of gree en waste recy ycling / comp posting. It alsso allows the e teacchings of hea alth and lifesttyle when stuudents are ab ble to learn n the benefits s of growing, eating and sharing fresh fruits and vegetables. Ofte en children will w become im mmersed in tthe idea, and d sugg gest that they y follow suit at home. It iss our hope to o enco ourage these e students to consider waays that they can take e the health and a environm mental benefiits and ideals s hom me, integrating g it into their lifestyle andd becoming more m envi ronmentally aware.

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Awa aba Colliery is s developing g a partnershhip by engaging and and supporting the local com mmunity. Thiss project assists students at the local sschool in lea arning the b benefits of he ealthy living; biological prrocesses, an nd allow ws students to t work outsiide while stilll focusing on n the scho ool curriculum m. Child dren are ofte en a good wa ay to teach eenvironmenta al and heal th benefits to o adults. Ado opting the coommunity garrdens at lo ocal schools and a encouraging environnmental think king throu ugh children could assistt in getting thheir parents to t have the ssame ideals at work and within their oown lifestyles s.

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HSEC C CONFERENCE 20012

CHA ARBON - ENV VIRO ONM MENT T Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Exc cellence and d Innovation ns Data Ind dustry Best Practice Land Reh habilitation n@ Cha arbon od quality reh habilitation off mined land is a minimum m Goo uirement by planning p and regulatory aagencies and d the requ com mmunity. Mining companie es that fail too deliver this aving to supp port large am mounts of rehab outccome face ha provvisioning in th he form of ba ank guaranteees until they y satisfy an e ever more de emanding min ne closure sttandards. c of land rehab is spennt on landforming The bulk of the cost B the most important pa art of and drainage construction. But the rrehab proces ss from a sus stainability peerspective is s the qual ity of the 30c cm skin of so oil material aand the vegettation. A litttle more time e and money y spent on thee planning, design, d mon nitoring and maintenance m of this vital llayer can lea ad to outsstanding resu ults. The techniques used u for a block of open cut mining re ehab at Cha rbon in 2007 7 have resulted in what iss generally rega arded as an industry bestt practice staandard of susttainable fores st rehabilitation. Thesse technique es will be app plied to all futture rehab projects at C harbon and continually im mproved to kkeep us at the head of th he pack. With h the cessatio on of open ccut mining, which could d be as soon n as 6 years in Charbon’ss case, we are a conffident the qua ality of our re ehab will be tthe least of our o worrries. Altho ough expected standards s of rehabilitaation are alw ways g, the curren rising nt expectation is to attain a stable landform with a self-regen nerating cove er of vegetati on. To have a high qual ity ecologica ally sustainab ble outcome is a bonus fo or the mini ng company y, the commu unity and ourr little piece of o the Biossphere. ehabilitation will w be continnued and imp proved Bestt Practice Re overr the life of th he mine. The whole Openn Cut Operattion is invo lved with influencing and d maintainingg the high sta andard. The form and tim ming of rehab b have an efffect on the lo ogistics of m many surface activities.

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HSEC C CONFERENCE 20012

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

u at Charrbon are eassily transferre ed to The techniques used er mine sites within Cente ennial and th e Industry. The T othe bene efits will be fo or our enviro onment and ffuture genera ations.

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HSEC C CONFERENCE 20012

CHA ARB BON – HE EALT TH AND A S SAFETY Y Field Nam me Title

Exc cellence and d Innovation ns Data Convveyor Guard ding Improvements at Chaarbon Colliery

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

a old mine many m of the cconveyor Cha rbon being an allations on the surface, within w the CH HPP and outbye insta area as of the underground pre e-dated AS17755. While there t was what appeared to be adequate guardding through hout the syste em an incide ent occurred (Sept 2008) where a fitte er put his h hand around a guard to put p a grease gun hose on nto a grea ase nipple. His H hand was s drawn into a large rollerr and he ssuffered seve ere injuries to o his hand th at could hav ve been mucch worse had d he not been n able to stopp the convey yor almo ost immediattely with a lan nyard. Amo ongst other re esponses to the incident the standard d of guarrding was rev viewed initially throughouut the CHPP and then n across the whole w mine. AS1755 waas used as th he stan dard for the review and an a external cconsultant wa as com mmissioned to o do an auditt of every connveyor on sitte agai nst AS1755.. We then prrioritised whi ch conveyorrs had the h highest expo osure and sett about desiggning, man nufacturing and installing new guards throughout the t convveyor system m in order of priority.

Therre is no requirement for guarding g on cconveyors to o confform with AS S1755 if they were installeed prior to the stan dard. Charb bon has gone e beyond com mpliance by d conveyor system s guardding to the sa ame upgrrading the old stan dard as AS1755. Altho ough costly this t is a one off fix and thhe benefits will w rema ain for a long g time. We have h set the bench mark now for o our guarding across the mine m and thiss will remain when guarrds need to be b replaced due d to damaage etc.

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

he first mine to upgrade oold conveyorr Cha rbon is not th ems to the new standard d of AS1755. At Charbon n there syste was a paradigm that the exis sting guardingg throughoutt our convveyors was adequate a to protect p our w workforce. The incid dent caused this paradigm m to shift andd focus more e on the requ uirements of the OH&S Act A that requirres us to cater for the a absent minde ed and careless employeee. Some off Centtennials olde er mines thatt have long cconveyor sys stems wou ld still have guarding g that is legal butt may not pro ovide the p protection required and could c learn frrom the Charrbon expe erience.

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CLA AREN NCE – HE EALT TH AND A SAF FETY Y Field Nam me Title

Exc cellence and d Innovation ns Data E–L Learning ( In nduction and Training)

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

ent taking persons througgh a lot of the eory Mucch time is spe train ning prior to practical p train ning being abble to comme ence and personnel with w no mining g experiencee struggle to conn nect to their new n working environmennt and Powerr point pressentation training. earning allow ws persons to o undertake ttraining witho out E-Le form mal facilitation n and is able to connect tthe actual wo orking envi ronment with h photo, anim mation and v ideo prior to pracctical experie ence in the workplace.

E- L earning can track the lea arners traininng (time, asse essment com mpletion and is accessiblee to review at a any time e) so can give e trainer information in reegards the learners prog gress. Trainin ng is delivere ed in a stand ard format and a there e is no variattion from trainer to traineer.

earning can be b integrated d into the foll owing aspec cts: E-Le Indu uction Trainin ng Equiipment Train ning Softw ware System ms Training (Pulse, Dyadeem, Citec) Visittor and Contrractor Inducttions

efits are: Bene Train ning is consistently delive ered. Efficciency of Training Facilita ation is improoved. Systtem is adapta able to various Training IIssues

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C CLA AREN NCE – EN NVIRONM MENT T Field d Name T Title Identifie ed Problem What, who o identified th he problem, ho ow the proble em was assesssed, what wa as the identified risk associatted with the pro oblem

Excellence e and Innova ations Data Keepin ng the place e in order – Centennial Clarence Co olliery’s provement Index. House ekeeping Imp ence Colliery y is the most visible part oof the mine th hat our The pitt top of Clare visitors s to site see ffirst. Althoug gh a book sh houldn’t be reead by its cov ver, the pit top reflects to vi sitors how organised and d professionaal a site is. Day by y day due to everyone’s busy b workloa ad, lack of ow wnership and d not seeing housekeepi ng as a priorrity, the pit to op became uunorganised and a this in turned t slowe ed down the process of th hings being eeasily access sible to take un nderground o or having som mewhere to store things as they cam me up from un nderground. Clarence utilises a Dolly car sys stem to trans sport person nel, materials and equipm ment to and fr from the pit to op to the und derground. T The dolly carr being the only way to gett everything into the unde erground, is tthe busiest area a of the pit top and as m more things came c out of the t mine, thee more items s were placed directly arou und the dolly y car or near by with the tthought to move them elsewhere e latter on. Witho out time perm mitting or em mployees hav ve a designated spot to place equipm ment that needed to go innto storage or o for repairs s, the area arround the dolly car, storage areas andd maintenan nce worksh hop became disorderly an nd unkempt.

So olution What, how w the solution n came about, how the e solution mittigated the risk

Not only with the isssue of the un ntidy housek keeping not rreflecting the e true profess sionalism of tthe mine site e, the housek keeping of thhe pit top cou uld have possibly lead to an environmental or safety s incidennt occurring at any time. A joint effort from th he Maintenance, Producttion and Envvironment departm ments, develloped an aud dit system to assess the qquality of housek keeping on th he pit top. The T initial aud dit gauged w where the site e was at and set down prioriities that had d to be fixed in the short aand long term m. In order to o assess imp provement in n housekeeping the inform mation from the audit was w grouped into similar categories, c such s as: geneeral houseke eeping, waste managemen nt, spares tha at required fu urther perma nent storage e or ment that nee eds to go to recycling/dis r posal. Thes e groupings equipm allowed d the site to ssee first hand where the issues weree and gave a e on issues that numero ological valve t were on site. An actiion plan wass developed covering c No 1 priorities, N No 2 Prioritie es and matters s for further cconsideration n. A colour code c was givven to each action a and wa as designate d to the resp ponsible depa artments withh a time fram me to comple ete the work within (see extract e from action a plan bbelow).

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How the ssolution goess beyond compliance

y extractive in ndustry site, has a large Clarence Colliery, llike any busy nt of activitiess constantly happening h on the pit top.. Materials and a amoun gear moving m aroun d pit top and d coming up and a down froom the underg ground are re elentless and d sometimes there is not always time to place things back w where they belong or eve en find them a home in th he first place. The pitt top of the m mine was gettting untidy and not portraaying the profess sionalism of tthe company y and the ma any great peoople who wo ork there. The sitte took it upo on themselve es to manage e the untidineess and show w some well ea arned pride in n their site an nd their place e of work. A way of man naging what was w happenin ng on the pit top and whe ere the site w wanted to be in the future was w develop ped in the form of a ‘Hous sekeeping Im mprovement Index’.

How the e solution is integratted into the business (that is, demonstrate ed continuityy of the solutio on at the site over a num mber of yearss) and indepe endent (that is, i the solution n is beyond ju ust one perso on driving the e outcome e - it is truly integrated d into how the e site o operates)

Be enefit Benefit of tthe solution to t Centennia al - how could d other sitess (or industryy) benefit from m the solutio on, has it be een adopted else ewhere?

The on ngoing work ccarried out on o the site to improve houusekeeping goes g beyond d Legislative Safety and Environmenttal compliancce and reflec cts that employ yees at Clare ence Colliery y want to set a good exam mple when it comes to site tidiness and mine produc ctivity. se the House e keeping im mprovements were drivenn from not only the Becaus environ nment depart rtment but inc cluded auditing, involvem ment and ass sistance from th he Production n and Mainte enance depa artments as w well, the improv vements were e identified and a motivated d by a groupp of employee es that all had their own le vels of involv vement and involving othhers. Becaus se the partia l extraction method m of miining is very dynamic and d there is equipment movin ng to and from the pit top p constantly 224hrs a day. Becaus se of this the ere will alway ys be ongoing issues withh housekeep ping from tim me to time de epending on n what is happening produuction wise, and what equipment no o longer need ds to remain undergroundd. With this in mind usekeeping iimprovement index has been b includedd within the the hou 2009/2 2010 Businesss Developm ment plan, witth ongoing auudits to be carried out ove er the next 12 2 months. The T site has set s another 220 % improvement target based b on the e findings of the first audit carried outt in Quarter 1 of the new fin nancial year. For ong going house keeping improvement an nd managem ment this improv vement indexx could be utiilised in the BDP B every ye year to make sure that go ood housekee eping becom mes ingrained d into the cullture of the site and not just a one off be enefit. w identifie ed as part off the initial au udit. Benefiits - Seventyy five issues were Becaus se some majjor changes had to be ma ade and infraastructure pu ut in place to combat the e issues such as the erec ction of storaage sheds an nd pallet racking, r a tarrget of 20% improvementt on the initiaal issues was s set to be recttified by end of June 2009. All the photos from the initial au udit carried out o were deveeloped into a slide show and a the photo os with captions of the issues were ruun on a loop on the pre-shiift meeting ro oom plasma screen. All employees e w were able to view the pho otos and cap ptions as they y awaiting the beginning of their shifts. This allowed d all employe ees (even those that wou uld generallyy only work within w the und derground) to o be aware of o the issues that were occcurring on the pit top with housekeep ping.

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Becaus se of the eassily identifiab ble issues and priorities inn the action plan p and be ecause emplo oyees on site e were aware e of the issuees and wante ed to see a significant s ch hange to hou usekeeping, all a Priority 1 iissues were rectified within the ffirst quarter of o 2008/2009 9 and the maajority of long g term issues were comple eted by end of the second quarter 20008/2009. Sheds were installe ed to enable the underco over and ordeerly storage of o equipm ment, pallet ra acking was installed to enable the tiddy storage of power dentified as needing to be cables, and items id b removed fo for storage elsewh here or for re cycling, were e removed to o open up furrther storage e opportu unities aroun nd the main area a of the pit top to allow w for equipm ment that is used more re egularly or in n transition between b the ppit top and underg ground to be stored efficie ently. Due to the proactivve attitude of the employe ees the 20% improvemen nt was achieve ed by end off the third quarter with a 50% 5 reductioon in all original identifie ed issues byy the close ou ut of the 2008/2009, abovve and beyond the target originally o sett. To keep all employees s up to date w with the prog gress of the imp provement in ndex, a montth to month ta ally was keptt on the notic ce board within w the pre e-shift meeting room, where all emplooyees could view it. The re--organisation n of the pit to op has meant that surfacee operators can c easily access a equip pment and move m around the pit top inn a safe man nner withoutt the risk of rrunning into items i improp perly stored. This has lim mited the opp portunities off environmen ntal and safe ety incidents aand/or near misses occurring on the pitt top. Innova ation & Tran nsferability – When developing d th he annual bu usiness plan for Clarencee for the 2008/2009 period, the site kne ew that house ekeeping wa as a major isssue on site. Unfortu unately matte ers of this so ort are not as s cut and dry as that of se etting targets s for safety orr production where you can c have a deefined targett to achieve e. There are e a lot of grey y areas around housekeeeping as the same issue on o site can occcur in differrent areas of the pit top, oover and ove er again. The sitte needed to work out a way w to have definite num mbers on whe ere we were with w housekee eping in June 2008 and have h a defineed way to se et a target to t achieve byy June 2009. The house ekeeping impprovement index allowed d all issues tto be tabulate ed in a way that t a target could be sett and progres ss towards th hat target on n a quarterly basis measuured. The ho ousekeeping improvemen nt index is a simple way tto identify iss sues and to set out an acction plan to prioritise the e tasks needding completion in the sho ort & long terrm. The idea a can be tran nsferred to anny site or ind dustry for not only housekkeeping but other o issues such as wasste managem ment. The ide ea of groupin ng the issues s into categories allows a holistic num mber to be set and then folllowed up witth further aud dits. The folllow up audits s gauge if the quantity of isssues have increased of decreased annd is an innovative way to allow all on site to meas sure where th he site is at aand what pro ogress has been made. It also allows an improvem ment percenttage to be se et (such as thatt of 20% at C Clarence) to give g the site motivation aand strive to possibly exceed the e target set, as was the outcome o at C Clarence. Th he use a plan a and colour co oding of all is ssues made pproblems easily of the action identifia able and sett down the tim meframes, work w requiredd and who wa as respon nsible to carryy out the task easy to understand.

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LAM MBER RTS GUL LLY – ENVIR RON NMEN NT Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Exc cellence and d Innovation ns Data Lam mberts Gully y Rehabilitattion Program m – Im mprovementts and Lessons Learnt uccess was variable v with erosion issu ues in Reh abilitation su som me areas. Identification an nd assessmeent undertake en with S Conserv vation. Risk oof long term stability s assisstance with Soil and revegetation n success no ot being acceeptable to reg gulator.

Asse essment of drainage d iden ntified areas of high unaccceptable flo ows during high rainfall peeriods. Redesig gned drainag ge. Allow ws rehabilitation result to be more accceptable to regu ulator and allo ow lease reliinquishment..

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

w enable rest of rehabili tation progra am to Lesssons learnt will be m more success sful and minimise costs inn re-doing arreas in the ffuture.

er design of rehabilitation n and drainagge will impro ove Bette reve egetation suc ccess to allow w lease relinqquishment. By B doin g it better the first time, less costs byy minimising redoing area as in future.

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M MAND DALO ONG G – ENVIR E RON NMEN NT Field Nam me

Exc cellence and d Innovation ns Data

Title

MO ORAN’S CREEK REH HABILITAT TION PROJ JECT

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

e 40 properrties at Man ndalong, Centtennial Coall owns some man naged by Sa anders and Associates A P Pty Ltd, to improve the sustainability and rural prodduction capability. Surrrounding land downers rais sed concernss with the Co ompany abou ut historical land management pracctices which h, have resu ulted in exte ensive clearring of nativve vegetatio on and seve ere erosion of o creek bank ks and drainaage lines acrross the valle ey. These his storical land managemennt practices and the effeccts of flood flows f resulte ed in sectionns of Moran’s creek dow wnstream, of Mandalong Road to wiiden from an initial width h of 3m to 20 0m and creek depths to iincrease from m 2m to 10m m exposing bedrock b along some seections. Cen ntennial Man ndalong identified that the e rehabilitati on and stabilisation of a section of Moran’s M Creek upstream oof Mandalon ng Road could d prevent further creek erosion e and eentered into a major proje ects partne ership with the Hunnter-Central Rivers Catcchment Man nagement Au uthority (CM MA) to equally fund the w works. ed on a The Moran’s Crreek Rehabilitation Projeect is locate ned property y leased foor cattle ag gistment Centtennial own requ uiring a colla aborative app proach with the lessee and a the Centtennial prope erty manage er Sanders aand Associates. The initia al protection works invo olved Sandeers and Ass sociates fenccing the Cree ek to exclude e stock from causing ero osion on the ccreek banks. This fence created the 3 km long by b 80 m wide e corridor along a the crreek and inncorporates nearby billab bongs. The fencing allow wed for imm mediate stabilisation of crreek banks by b emergentt grasses annd prevented d further erossion by cattle. To proviide stock w watering poin nts and imprrove pasture e nutrient cy ycling, Sandeers and Ass sociated insta alled concrette gravity fe eed water taanks in locattions of poorr pastures areas, away from f the Creeek, to impro ove soil nutriient cycling. Tube e stock planting was s selected as the prreferred reha abilitation me ethod for the e site. Prepparation for planting p inclu uding de-com mpacting the e soil by rippping along the land conttour to a dep pth of 400 mm and sprayying herbicide along thesse rip lines to remove competition from aggre essively grow wing grasses s. Tobacco and Blackbberry weeds in the corriidor were also sprayed with herbiccide to remo ove the com mpetition from m these species. Gloobal Soils System prep pared these areas and then plantedd 1500 nativ ve tube stoc k species to t re-establish the locaally found redgum gh-bark apple e wood fores st communityy across the e 3.8 ha roug corriidor. The tube stock pla anted in Novvember 200 08 were main ntained by installing tree guards annd watering during theirr three montth establishm ment period, contributing g to the

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high rate (85%) of juveniles being succeessfully esta ablished by March 2009 9. Groundcover speciees were fo ound to mini mise erosio on of expos sed soils onn creek ban nks recolo nising these areas.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

The Mine’s development d consent requires a Land Man nagement Plan P (LMP) detailing thhe protectio on and man nagement off rural land holdings. T The Moran’s s Creek Reh abilitation Project we ent beyond the com mpliance requ uirements of the LMP as re-estaablishing a native vege etation corrid dor to impro ove the creeeks’ sustaina ability is not a requiremen nt of the LMP P. s demonstrated to the bbusiness tha at CMA The project has nerships are e a viable solution s to ffunding non mining partn relatted rehabilita ation works on o Companyy land holdings. The land manageme ent techniques used to protect watterways from m stock relate ed erosion ha ave been addopted in the e Mine’s LMP P.

on for Moran n’s Creek haas demonstrrated to The rehabilitatio Centtennial that the rehabilitation technniques implemented with huge succe ess in rehab bilitation minees can be used u on sma aller scale rurral holdings to t re-establissh native veg getation on ccreek system ms and reduce the loss of agriculturral land alon g catchmentt water ways.

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M MAN NDAL LONG G – HEA H ALTH H AND D SA AFET TY Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Exc cellence and d Innovation ns Data CM M RIB PROTECTION SYS YSTEM w years 7 peo ople have beeen injured frrom Ove r the last few ribs during the Development D mining proceess. A comm mittee s, was set up with a vast array of experiencced operators depu uties, produc ction coordinators & enginneers. Many y ideas were e thrown abo out to improve the safety and well being of the e employees. An a all over new rib r protection n system wass developed to engi neer out kno own and foreseeable safeety risks. Thiss is actually a number of innovations w which have come c abou ut from the poor p rib conditions encounntered at Man ndalong. The system inclu udes:  Inbye Po oly rib protec ctors  3rd stage e rib bolters  Outbye Metal M rib protectors (withh Hydraulic extensio ons) In ad ddition, the operators o were not cuttingg and bolting g simu ultaneously fo or safety rea asons, causinng loss in prod duction. s to design an integrated system of rib The solution was ection including all 3 elem ments. Nonee of these ele ements prote have e been done before. The out bye me etal rib prote ector was deeveloped with h conssultation from m the OEM Sandvik S and aall MDG requ uirements forr crush injurie es met. The ooriginal version of the o outer metal rib r protector we w allowed tto fit a hydraulic raise e / lower cylin nder but did not initially aas we did nott have the h hydraulics to o support it, so s we fitted aan adjustable e metal bar. We have fittted all machines receivingg an overhau ul with hydrraulic raise lo ower extension on the staandard and outer o meta al rib protectors due to ne ew rib boltingg valve bank ks that are d designed to do d this. The outbye meta al rib protecto or protects thhe operator whilst w insta alling the rib bolt. This are ea is unsuppported until th he new rib b bolts are insta alled, and as s a result thiss device give es the operrator enginee ering protection. The devvices are engi neering rated 500kg botttom section & 125kg top section and as such hav ve been fitted d with decalss as per MDG G35 stan dard. AS402 24.1 for crush h injuries waas also used. The standard me etal rib protection device protects the roof bolt operato or & rib bolt operator and is rated the sam me as the outb bye metal rib b protector. The 3rd stage rib b bolter was s designed aand successfully impl emented in consultation c with Sandvikk. This enablles the rib b bolter to extend 500mm more m yet still collapses to the origi nal dimensio ons therefore e still enablinng single pas ss

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Field Nam me Title Innovation title

Exc cellence and d Innovation ns Data CM M RIB PROTECTION SYS YSTEM drillin ng. Thiss made rib bo olting a lot sa afer as the heead plate cou uld then n reach the rib and suppo ort it whilst boolting. This could not h have been done previous sly as the ribb bolter would d not reacch the ribs. In n bad rib conditions Manddalong has reco orded rib blow w out as muc ch as 1.2 m. Additional benefits have e been the ease of bolting up breakaw ways and DC CB nich es etc. The in bye Poly y Rib Protector was desiigned and succcessfully imp plemented to protect the ooperator whilst insta alling the outter roof bolt. Sandvik wass also consullted in rega ards to this but was not sh howing any iinterest in gning this. So APM and we desig S Mandalong contacted A e desig gned it togetther. The dev vices are enggineering ratted to 750kkg for both th he top and bo ottom sectionn therefore satissfying MDG3 35 standard. Desiigning the sy ystems posed d significant challenges as a this had never been done before. Thesse challenge ers for the ‘po oly inbye rib protector’ we ere: 1. The drill rig when tiltted out only jjust misses the t standarrd metal rib protector p so itt would hit any extensio on made inby ye of this. Drriven from the risk assessm ment Poly wa as chosen. 2. The opeerators put th his hard up aagainst the rib. It needed to be strong g enough to sstop the rib falling on the operator. o 3. It needeed to be retained in the foorward position so it does no ot get caughtt when tramm ming in again nst the ribs. 4. It could get caught on o rib bolts w when trammin ng ards. backwa 5. It wouldd be limited in n height from m making surre when installing roof mesh it was clear and did not interfere e with this process. 6. Had to swivel s out so o we could sttill get in from m either the platfform or from the rib side to perform mainten nance and lim mit any pinchh points. The e initial design was w to have a self closingg spring but this would have h caused maintenancee issues long g term. Also the e physical siz ze of such a hinge would protrude e out inhibitin ng the flittingg process and d be prone to o damage.

7. The drill motor tilted out would hhit it so the deesign had to allow a the drilll motor to puush past it an nd also not catc ch it on the way w back dow wn. Afte er some time e of using the e Poly Rib P rotector therre were som me further im mprovements s that were m made. This ca ame abo out again from getting a group g of macchine operators tog gether to help p come up with recommeendations & ideas of imp provement. The T change managemen m nt process wa as foll owed for eve ery change made. m This inncluded risk asssessments and documen ntation for all changes.

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Field Nam me Title Innovation title

Exc cellence and d Innovation ns Data CM M RIB PROTECTION SYS YSTEM The ese were:

1. Replacing the Poly hinge h with a metal hinge and making the diameter of the rod laarger. This was w to strength hen up the hiinge and elim minate dama age as this was s the only are ea that was ggetting dama aged.

2. Put 45 deg d chamferr on back edgge of the metal hinge so o rib bolts wo ould not catcch on it when n trammin ng in reverse e, when opera rators don’t re etract the rib protector. p

3. Counterr bore the thrree mountingg holes so thhe bolts would sit s inside the metal hinge and be prote ected.

4. Put a kick in the leading edge innstead of justt a chamfer to help it ru un over the riib and stop itt catching g it.

5. The origginal estimation was 3 maagnets howeever this was s revised to 5, 5 to retain it with more sttrength but still allow the Po oly Rib Protecctor to be hin nged out easily.

6. Round the t bottom le eading edge to allow it to o ride

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d

over larrge topers an nd not get caaught. The drill motor tilted out would hit it so thee design had d to allow w the drill mo otor to push past p it and allso not catch h it on the w way back down. What we e did was to have a sepa arate secttion at the top p hinge out in ndependent of the bottom m. This was retained bettween the tw wo with one laarge magnet to still lock the top & bo ottom section ns together w with a lip jointt desig gn to give maximum m joint retention sttrength. Wha at was happ pening is the e rib was falling away at t he top bye up u to 1.2 m meters from standard rib line causingg rib spall at the t botto om stopping the bottom of o the Poly R Rib Protector to swivvel out but the top was fre ee to move oout to give the drill moto or clearance to tilt all the way out andd support the e roof. Whe en the drill motor was retrracted we puut a 45 deg le eading edge e on it so the e drill motor would w not cattch on the Poly Rib Prottector on the way down. The CM rib prote ection system m complies aand supersed des all statu utory requirements. Non e of the 3 ele ements are statutory s requuirements att pressent but certa ainly may be incorporatedd into them in the futurre. The metal rib pro otectors are now Sandvikk standard is ssue, as are tthe rib bolting g valve bank ks incorporatted to supporrt them. The 3rd stage rib b bolters can n now be purc rchased as Sandvik S stan dard. The Poly Rib Pro otectors can now be purcchased as standard. Theyy have been positively ac ccepted from m mines with bad ribs. h been driv ven from thee work force wanting w Thiss innovation has afer work plac ce. a sa n place sincee early 2008 and The innovations have been in

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Field Nam me Title Innovation title continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Exc cellence and d Innovation ns Data CM M RIB PROTECTION SYS YSTEM will not opera ate the machine with out them fitted. we w Thiss innovation is the culmination of 100’ s of hours off deve elopment, co onsultation & design. It foollows good engi neering principles & proc cesses to proovide a cleve er & uniq ue solution to t a known & foreseeablee risk. Brain nstormed so olutions with a vast array of experienc ced operrators. Many y ideas were thrown abouut to improve the safe ety & well being of the em mployees. Drew w sketch con nsulted Used d the idea off a magnet to o close the P Poly Rib Spra ag from the A ABM Magnettic Mesh Loc cator conceppt. Reviiewed Improved & Implem mented. Therre has been many consultation meetiings to discuss imprrove & brain storm ideas.. Every innovvation had a Tool Box Talk commu unicated to workforce w inc luding feedb back and notification as a to change e as part of thhe change man nagement pro ocess. Riskk levels were identified by y a number oof processes. Firstly the m many inciden nts which dro ove the innovvation have a risk asse essment as part p of its des sign and impplementation. The chan nge management process which incoorporates a RA R was used d to ensure that no new risks r were inttroduced as a result of im mplementatio on. The issue was clearly identifiied & solved . k Dramatically reduced from 9 mod derate risk, to t 17 Risk acce eptable risk k. Hyd raulic hose failures The Poly Rib Pro otector has stopped s the rrib falling in on o the drill rigs virtually eliminating hose h damagee on the rigs s. Com mbining this with w the hose e manifolds ddesigned with h Bere endsen we have had an 86% 8 reductioon in machine down time e associated with hydraulic hoses from m MG5 to MG G8. We h have had several reporta able potentiaal oil injection n incid dents in the past p and man ny blown hosses costing conssiderable time and posing g a safety rissk to personn nel. Sincce installing the t in bye Po oly Rib Protecctor there ha as been no re eported injurries to operattors from ribss during the cutting proccess compare ed to 7 injuries previouslyy before impl ementing this. Theyy can now sa afely cut and bolt and be protected incre easing not on nly safety but improving pproductivity. It is cclassed as a safety devic ce and we w will not operatte the Conttinuous mine er with out the rib protecto tors fitted. Therre have alrea ady been oth her mine sitess incorporate e& requ uesting this system s be implemented oon their new macchines. All ele ements can be b purchasedd and are no ow stan dard issue. Can be used on any undergrround miner. We d designed & fitted f a Poly Rib Protectioon system fo or our JOY Y12CM Minerr at Mandalong.

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HSEC C CONFERENCE 20012

M MANNER RING – EN NVIR RONM MEN NT Field Nam me

Exc cellence and d Innovation ns Data

Title

In ntegrating Environm mental Risk k Managem ment in nto everyday Operattions

Innovation title Id dentified Prroblem

What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

When Com mmon Practice beco omes acce epted as the only solution n, the pote ential risk k to d environm ment can be over lo ooked. safety and

Risk base ed auditing g by the m manageme ent team iden ntify poten ntial issue es, instill ownership, forge good mana agement practices and solutions.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

A riisk based audit of the opera ations iden ntified the management pra actice em mployed in n the recllaim tunnel as bein ng one wiith high risk r of imp pact on th he environ nment witth potentiial for off site polluttion. e solution was simple The w structur res to dire ect runoff and wash hdown Flow watter from the reclaim tunnell to two inline sum mps. The sumps provide co ontainmen nt and resiidence tim me for contaminated d flows to settle outt. e sumps are a includ ded in we eekly and d post The storrm event and maint tenance in nspections s with reg ular clean ning under rtaken or w when requ uired.

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How th he solution goes g beyond complian nce

The e integra ation of risk as ssessment and aud diting in nto not only environm mental man nagementt but all operations o s at Mann nering has s provided a mechan nism to m move the culture of “ “that’s nott my job ” or “my w worry “to one o of a tteam approach to identifyin ng and so olving pot ential ma anagemen nt issues and pra actices o the way we do bus siness. into b a simp ple operattion of Wh at would seem to be aning dow wn and wa ashing aw way the pro oblem clea with hout cons sideration of the b big picture e risk, has s the pote ential to significant s tly increas se the cos st to the bu usiness.. e approa ach The own nership of resp y ponsibility

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

has instilled d ma anagementt

an overall o areas s of

The e accepttance off enviro onmental risk con nsideration ns into Mannerin ng opera ations, indiividual and responsibilities team iden ntification n of issues, potentiial impactts and solu utions ha as ensured that environm mental con nsideration ns and riisks are included in all asp pects of ou ur operatio on

The e integratiion of env vironmenttal risk au uditing and d actions developme d ent ensure es owners ship in ope erational areas, de elegates responsib bilities and d provides s a holistic c risk base ed identific cation of potential impacts and offerrs realistic and metimes simple s so olutions tto issues s that som hav ve otherwise been overlooke o ed or prev viously unid dentified.

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HSEC C CONFERENCE 20012

MAN NNER RING G – HEAL H LTH AND D SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data Stra p Lifter

Innovation title Id dentified Prroblem

What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

3 304 Panel prroduction pro ocess team hhighlighted is ssue m manual hand dling of loading straps onn the roof bollter [an a average of 90 9 straps are used each dday in one pa anel].

A Also highligh hted in manual handling ttraining that current h handling was s not ideal

Problem was s assessed by b process im mprovement team

Manual hand dling injuries was identifieed as the risk iinvolved in th he task, spec cifically shouulder, neck and b back injuries s.

Mannering safety s statistics confirmedd that manua al h handling inju uries were inc creasing.

Solutio on

What, how the solution came about,, how the so olution mitiga ated the risk

T The 304 production process team woorked on a nu umber of potential alternatives o a to the manuaal loading of straps.

O Once the 304 process te eam selectedd the most appropriate solution, a s a Mannering M Froontline Managemen nt team forma alised the Strrap Lifter as a ccontinuous im mprovementt project.

By introducin ng the Strap Lifter it ELIM MINATED the e m manual hand dling required d to load straaps to the roof b bolter.

Process alre eady complie ed with industtry lifting limit of 2 20kg, howev ver as a repe etitive processs this was not cconsidered adequate a as multiple liftinng equates means m rrisk of injury over time is increased.

A Additionally, the risk of trrips, slips andd falls was rreduced.

T The Strap Lifter was built and rated bby Macquarie e Manufacturin ng.

Risk assessm ment was co onducted on ddesigned Strap Lifter.

S eveloped, rev viewed and iimplemented d. SWP was de

T The Strap Lifter has been in use for 6 months and d the design has been d b slightly modified as a result of process iimprovemen nt team meetings.

A purpose built pod has been designned and built to ffacilitate the transportatio on of the straaps.

T The Strap Lifter was designed and peerfected by the t w workforce an nd they require no encouuragement to use it.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

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Benefit

Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

For a numbe er of years, Mannering M haas been cconcentrating on manual handling ass the most ssignificant ca ause of injury y at our workkplace.

By introducin ng the Strap Lifter it ELIM MINATED the e m manual hand dling required d to load straaps on the ro oof b bolter.

T There have been b no injuries as a ressult of loading g straps ssince the implementation n of the Strapp Lifter.

T This will contribute to a reduction in innjury manag gement ccosts.

A As a result of o this safety innovation, tthe process time t rrequired to lo oad straps has been signnificantly reduced (a p productivity survey s show wed a reductioon from 50m mins to 10mins for lo oading straps s).

T This has incrreased bolter availability by an average of 4 40 minutes per p shift, which is significa cant as CM delays d due to waitin ng on bolter is our major ddelay.

T The process s improvement teams aree currently wo orking o on expanding the system m to include oother materia als ssuch as mes sh modules.

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HSEC C CONFERENCE 20012

MY YUNA A–E ENVIRON NME ENT Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Exc cellence and d Innovation ns Data Integ grated Susta ainability blem Prob Huntter Water was w to cons struct a waaste water pipeline acro oss Centenniial Myuna’s property. Thhis has the potential p to ccause erosio on and sedimentation, ppoor water quality, vege etation remov val and safetty concerns. The pipeline was w designed in conssultation wiith site perssonnel som me five years prior to the prroposed consstruction. Re ecords of me eetings weree kept, howe ever no curre ent staff mem mber on site had attendeed or been involved in th e pipeline de esign phase. blem identiffication Prob The construction n of the pipe eline was raaised at the weekly revie ew meeting, after pipeline contractors rs contacted the site nductions an for in nd meetings. The pipelinne was to be e thrust bore ed under Wa angi Creek, which runs through Cen ntennial Myu na property y. It was recognised r that there was a pote ential risk of an a adverse environmenta e al or safety in ncident. Prob blem Asses ssment A ffull Dyadem m Risk Asse essment waas conducte ed with vario ous staff representatives and the ppipeline con ntractor. Follo ow up mee etings were held with tthe Departm ment of Com mmerce, Hun nter Water an nd the pipelinne contractorr. Issu ues The construction n of the pip peline has thhe potential for the follow wing environ nmental issue es: 

10-13m disturbanc ce zone, rresulting vegetatio on and poten ntial habitat rremoval;

Sedimen nt and erosio on control isssues; and

in n

large

 Runoff frrom acid sulp phate soils. The construction n of the pipeline has the need for the e safety man nagement of issues includ ding:

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Confined d spaces;

Lifting eq quipment;

Unregisttered machin nes;

Uncontro olled access to site;

Excavation; and

Working near power lines.

mmunity Con nsultation Com Myu na recognised the statutory objectivve of the OH H&S Act 2000 0 No 40, Parrt 1, 3. Objec cts ((f) to develo op and prom mote commuunity awaren ness of occu upational hea alth and safe ety issues. Thiss clause wa as achieved in this prroject management

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HSEC C CONFERENCE 20012

meth hod through enhancing the objectivees of the OH& & S Act by p promoting aw wareness thro ough the bussiness comm munity. It was seen as a beneficial process p thatt incorporate ed best pracctice OHS application n and bussiness com mmunity enga agement. Seve eral meetings were co onducted beetween Cen ntennial Myu na, pipeline contractor, Hunter Watter and Department of C Commerce discussing d the t issues raised in the risk asse essment and d risk mana agement conntrols to ov vercome them m. Discussions looked att options usiing the hiera archy of conttrols which in ncluded: 

moving the t designed d location forr the pipeline e,

changing g machines,

mechanical solution ns to resttrict infringin ng the exclusion zone to po ower lines,

 erosion and a sedimen nt control barrriers. Solu ution A rig gorous mana agement plan n was put in pplace that included:

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

adoption n of alternative equipmeent from that which was prop posed;

relocatio on of piping; and a

a series of environmental protecttive measure es.

Altho ough the pipeline p contractors aree not engag ged by Centtennial Coa al, the cons sultation proocess has enabled e Centtennial to work w with the e business ccommunity to set a num mber of guidelines to prote ect both enviironment and d safety of th he community. Environm mental and risk controlls were gene erally more e rigorous than the normal pro ocesses emp ployed by the e pipeline con ntractors. n and supervision proceess has seen n many The consultation mbers of the e communitty participatte. The stafff and mem com mplex environmental iss sues aroundd the project, has resu ulted in en nvironmental issues bbeing adoptted by electtrical, mecha anical and sa afety personnnel on site. The process has s meant that a range of ccompanies involved in th he construction and planning of the ppipeline understand the i mportance placed p on environment, hhealth and sa afety. The identification n of the prob blem shows tthat management of thesse issues is already a endemic to the m mine’s system ms.

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HSEC C CONFERENCE 20012

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

The benefits to Centennial Myuna incluudes a reduction in amount of vegetation v cle earance reqquired and no water the a qual ity issues ca aused by the project. Othe er benefits include tha at the highh safety sta andards Centtennial Coal have set have been addhered to. Workers W on tthe Centennial Myuna site s have beeen provided with a safe e environmen nt to work in. Mem mbers of the community have seen thhe high mea asure of impo ortance we place on the t safety oof people and a the envi ronment. Mem mbers of gov vernment dep partments weere also exp posed to our duly dilig gent approach enhanncing Centennial’s repu utation. By implementiing the strict s meassures to ensure envi ronmental and safety managem ent on ou ur site, Centtennial Myun na hopes that a greater deal of awa areness in m methods of work w will be adopted a by tthe companies and furth her business community involved i in thhe project.

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HSEC C CONFERENCE 20012

MYUN NA – HEA ALTH H AN ND SA AFET TY Field Nam me

Exc cellence and d Innovation ns Data

Title

The Penc cil Sharpenerr

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

d tips from roof bolting steels is a ta ask that The removal of drill equired to be done on a re egular basis at most mining is re u the e installationn of roof bolts s. operrations that undertake Drill tips have be een removed by striking tthe tip with a ham mmer to loose en. This meth hod has the ppotential to send s fragm ments flying,, with a poten ntial to causee impact injuries. The OH&S comm mittee recogn nised the low w level of con ntrol (PPE E) and decided to develo op a higher leevel of contro ol. Disccussion with suppliers s has s lead to thee developmen nt of a drill ttip remover. m Fluid Powe er was consu ulted and devveloped a prroto Cram type e tool to remo ove used drill bits. The tool clamps the end of th he drill steel aand applies a rotattional force to o the tip to lo oosen the tipp. This is don ne insid de the tool. There T is no ex xposure of thhe operator to t movving parts or flying f fragme ents. The proto type has been trialled at Myunaa and feedba ack give n to the man nufacturer forr modificationn. The Drill Tip Rem mover uses the t hierarchyy of control to o provvide a higher level control than is currrently used by b the indu stry. An Eng gineering con ntrol > PPE. Thiss process allo ows for the re ecovery of ussed drill bits for clea ning or recyc cling. (Bits re ecovered afteer being hit with w a ham mmer are ofte en damaged). Myuna is w working with Sand dvik to recov ver the used drill bits. Thee tungsten ca arbide can be recycled.

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

velopment. The solution is still under dev as been enthusiastically welcomed w byy the OH&S It ha com mmittee and operators. o Upg raded versio ons will be fittted to mobilee roof bolters s in all unitss at Myuna.

Benefit

k, flying fragm ments eliminaated, reducin ng the Red uction in risk of eye and fa acial injuries in particularr. risk o The device can be b easily retrro fitted to anny Mobile roo of bolte er and to boltter miners. Red uction in nee ed for raw ma aterials by reecycling drill bits.

Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

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HSEC C CONFERENCE 20012

NEW WSTAN - ENV VIRO ONM MENT T Field Nam me

Exc cellence and d Innovation ns Data

Title Innovation title

Hydrro-mulching Solutions

Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how olution mitiga ated the risk the so

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

wstan rehabilitation needs s to be comppleted promptly to New stab bilize disturbe ed areas to prevent p soil eerosion and rer ablish vegetation. Often th his disturbannce is in high profile esta area as. od fiber Hydrromulching – application of a slurry oof water, woo mulcch, seed and d fertilizer to prevent p soil eerosion and provide an e environment / medium conducive to pplant growth.

New wstan could simply s direct seed the sitees, however this wou ld not prove as successful or environnmentally ben neficial as h ydro-mulchin ng (short time period for vvegetation esta ablishment an nd erosion prrotection bennefits). wstan explora ation and methane gas drrainage sites s are New now w hydromulched with a mix of local nattive tree spe ecies and sterile exotic c grass (cove er crop speciies). Newsta an reha abilitation has s recently be een successfful in recordin ng germ mination of bo oth natives and a exotic grrass species. Vege etation estab blishment period is signifiicantly reduc ced.

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

sure to stabillize and rehaabilitate distu urbed Succcessful meas sitess. Especially effective on sloping terraain. Opportun nity for use elsewhere at a other Cente ennial sites dduring reha abilitation.

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HSEC C CONFERENCE 20012

NEW WST TAN – HE EALT TH AND A S SAFETY Y Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Exc cellence and d Innovation ns Data Intro oduction of VOIP V phones into Undergground Phone e syste em. VOIP P- ( Voice ov ver internet protocol) wstan utilizes the DAC IS Phone systeem. Newstan n’s New prob blem was the e reliability off these phonees the cost of o repair and the exorbitant turn aroun nd time of reppairs. The loss of phon nes in the fac ce or outbye areas was cconsidered to o be a safe ety risk. Perso onnel need to have reliabble phone com mmunication and a an adequate numberr of phones. es a heavy flow of data trransfer for The mine require nitoring purpo oses. This tra ansfer of infoormation now w days mon is tra ansmitted ac cross fibre op ptic cable. Thhe technology of toda ay allows for telephone co ommunicatioon to also be transsmitted acros ss this mediu um. The VOIP phone es due to their low cost a nd the acces ssibility of ha aving fibre ne etwork to all major outbyee plant allow ws a phon ne to be at every work station. hones were in the past used but requuired a coppe IS ph er line to be e also run to these sites. This also addded to the cost c and no d duplication off cable netwo orks. This haas the added benefit of la abour cost sa avings. es negate the e need for duuplicate cabling and The VOIP phone e will be the main m line forr all data and voice in th e future fibre mmunication around a the site. Whereveer internet ac ccess is com p may be utilized. avai lable VOIP phones ure superviso ors will be ab ble to expandd on the original Futu syste em by adding VOIP cards to the curre rent telephon ne syste em. Futu ure users will also be able e to take advvantage of Wi W Fi VOIP P systems th hat integrate with current telephonic syste ems.

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HSEC C CONFERENCE 20012

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

efits in the use of VOIP phones p Bene 

Easily co onnected into o existing fibbre optic netw work.

Reliabilitty of the phones

Initial co ost of VOIP phones is low w.

Repair cost c of VOIP phones as ccompared witth DAC phone is s extremely lo ow.

Accessib bility of these e phones at eeach site where information transfer occurs. o Pum mps, transform mers, etc

Less reliiant on IS ph hones and theerefore less congestiion on IS circ cuit for chargging of critica al IS network..

Minimal amount of IS S phones thrroughout the mine

Less cos st of Ausdac phones/ spaares.

Expanda able and ada aptable for W Wi Fi VOIP sy ystems.

IS Wi Fi systems now w on the marrket.

Cost of a VOIP phon ne approx $2200 as compa ared with an Ausdac A phon ne $2500+

Disa advantage 

Unable to t be used in n hazardous zones

Loss of phone p when no undergroound power.

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HSEC C CONFERENCE 20012

S SPRINGV VALE E - EN NVIR RONMEN NT Field Nam me

Exc cellence and d Innovation ns Data

Title

'Qua antum' Energ gy Efficiency Hot Water S System for th he main Mine e bathhouse.

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

w was av vailable to coover the shiftts with Not enough hot water ers for showe ering in the m main bathroo om at the l arger numbe end of shift, this t began to o occur durinng the cold Winter W the e perio od. This had d been raised d by both thee Local Chec ck Insp pector and Em mployee Rep presentativess and had be een iden tified as a po otential ‘industrial issue’ aat the mine. Upo n investigatio on, load flow w (maximum ddemand of th he supp ply cable) to the bathhouse was foundd to be insuffficient to in crease hot water w supply. The existingg cables wou uld need d to have been upgraded d and transfoormers replac ced in orde er to supply more m power for f extra hot water system ms. Thiss was expected to be a large cost, so other solutio ons were e investigated.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

s was investigated aas a cost-efffective The ‘Quantum’ system mal ‘electric’ heating methhods use ene ergy to alterrnative. Norm direcctly heat the water. This can c never bee greater tha an 100% % efficiency, but is more likely betweeen 60% - 98% effic ient. The ‘Quantum’ heat h pump on nly uses elecctrical energy y to run the ccompressor, not to heat the t water. Thhe heat enerrgy actu ally comes from the atmo osphere. Thiis allows an effic iency of up to t 300% or more m (e.g. 1kW kW of electric cal enerrgy into the heat h pump ca an transfer 33.6kW of heat enerrgy into the water). w

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly d into how the site operattes) integrated

s provid ded the addittional hot wa ater The ‘Quantum’ system uirements and more wate er heaters, w without additio onal requ ongo oing energy expenditure\\consumptionn. Inste ead of simply y upgrading the t existing ssystem to me eet dem mand, the exitting hot wate er systems w were able to be b repla aced with a larger numbe er of superiorr energy-effic cient syste ems without the need forr a new transsformer, cablles or switcchboard mod difications. ed since Mid 2008 and has The system has been installe ved the issue e and more hhot water is now n effecctively resolv avai lable.

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HSEC C CONFERENCE 20012

Benefit

Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

The ‘Qua antum’ syste em was able to deliver mo ore hot water with in a more energy-efficcient way. Th his reduces ongoing ene ergy consum mption and co osts.

Hot wate er volume \ Energy E Conssumption Comparison: o The old system had 12 uunits @ 315 litres l each with a power usagee of 10kw/h/u unit. This gives a total of 3,7880 litres with a total power usage e of 120kw/hh. o The ‘Quantum’ system hhas 18 units @ 315 litres each with w a power uusage of 2kw/h/unit. This T gives a ttotal of 5,670 0 litres with w a total power p usagee of 36kw/h.

The ‘Qua antum’ syste em reduces G Greenhouse Gas emission ns by being up u to 5 timess more efficie ent in the enerrgy required to t heat wateer when comp pared to the prrevious insertion elementt electric water heaters.

The exis sting new transformer andd cables did not require replacement r or the switchhboard requiire modifica ations. The upgrade costss would have e been significant; o 2.5Mva 11kv v/415 Transfo former approximate cost $75,000 0. o New cables, installation aand switchbo oard modifications s approximattely $50,000 0. o 6 more old style s 415V waater heaters @ $2,500 ea approximate ely $15,000 (@ a). o Plumbing an nd Electrical ccosts (for wa ater heaters) estimated at $1 0,000 o Thus, total upgrade costss would have e been approximate ely $150,000

Due to th he governme ent energy effficiency grants of the time, the upgrade e costs to thee ‘Quantum’ system were w FREE. The governm ment supplie ed funding for f the projec ct through thhe RECS reb bate scheme.. Thus the prroject had miinimal costs of $61,000 (for Plumbin ng and Electrrical). This gave g a total upg grade savings of $89,0000.

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Oriiginal Hot Wa ater Systems s (12 units)

New Quantum Q Hott Water syste ems (18 units)

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Existing Tra ansformer (n o longer requiring replac cement)

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S SPR RINGV VALE – HEA H LTH AND D AFET TY SA Field Nam me

Exc cellence and d Innovation ns Data

Title

Sprin ngvale Longwall 412 Tak ke-off Roadw way Support System

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

ny problems have h been experienced w with previous s Man Long gwall take-offfs at Springv vale Mine. T The Longwall takeoffs have evolved over the prrevious 12 Loongwall reloccations, with different ideas and technniques being g tried overr that period. It was recognised from previous iss sues that a better systtem was required. The problem was s 4 fold, 1. Injures and near n misses were experieenced and th he risk o of physical in njuries to em mployees duee to; faceline b blowout from m failure of plastic mesh, hand bolted face b bolting syste ems or spray grouted stylle cconsolidation n/retention products. 2. T The goaf edg ge reeling in while emplooyees are ere ecting ttimber “pigsttys” or “link n locks”. 3. V Ventilation is ssues during the locationn due to the goaf g cclosing off th he face, caus sing ventilatioon and diese el p particulate is ssues as well as limiting tthe number of o m machines ab ble to work on the face caausing efficie ency p problems. 4. Longwall relo ocation efficiency and Buusiness Risks tthrough reloc cation delays s to the operration.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

The “Springvale Longwall 412 Take-off R Roadway Sup pport ments; Systtem” incorporating 6 elem 1. ““Huska” style e mesh. 2. S Self drilling “Hilti” “ bolts (to retain the ““Huska” style e mesh tto the face frrom a remote e location beehind the AFC C) 3. Fully grouted d 8 metre Bo owen roof boolts. 4. PUR to cons solidated frac ctured roof d uring the fac ce boltu up. 5. Hydraulic “R Rok Prop”s (h hydraulic eneergy is dissipated ffrom these props p once in nstalled). 6. C Cement filled d “Cans” (are e quickly insttalled using an a Eimco QDS attachment). All ccomponents except e the “H Huska style m mesh and the “Hilti boltss are currenttly utilised forr many otherr tasks throug gh the mine e, some have e been used in the Longw wall take-off situa ation as a rea active solutio on once probblems were evident. e The “Huska” style mesh has been used aat the mine prevviously, but not down the actual face aand the “Hiltii” self drillin ng bolts have been used successfullyy at Angus Place P for fa ace mesh retention. Thesse six compo onents have been used to together to develop

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a pro oactive soluttion to mitigate risks that have occurred durin ng previous Longwall L relo ocations.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Man ny different te echniques ha ave been trieed over the precceding Longw wall relocations, all with vvarious issue es. The “Sprringvale Long gwall 412 Take-off Roadw way Supportt Systtem” incorporates a mixure of techniqques to develop a syste em which offfered the bes st safety andd efficiency expe erienced on a Longwall ta ake-off face aat Springvale e Mine to da ate. All ccomponents of o the “Springvale Longw wall 412 Take e-off Road dway Suppo ort System”, except e the “H Huska style mesh m and the “Hilti bolts are curren ntly utilised foor many othe er tasks throu ugh the mine e. Follo owing the success of the system duri ng the 412 Long gwall relocattion, it is plan nned to utilisee this system m in futurre Longwall moves. m

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

A sa afer and more e efficient Lo ongwall take--off system. The majo or benefits off the “Springv vale Longwaall 412 Take--off Road dway Suppo ort System” is s the reductioon in time an nd likeliihood that men are expos sed to potenntially hazardous situa ations and the reduction of o Business risk. For exa ample; 1. S Self drilling “Hilti” “ bolts us sed on the faace eliminate es the n need for men to be exposed while haand bolting on the A AFC, clearin ng blocked ho oles, installinng chemicals s and p pushing in bolts. They are installed ffrom a remotte llocation behind the AFC.. 2. ““Huska” style e mesh along g with “Hilti” bolts offered d tight fface retentio on as oppose ed to the facee slabbing that has b been experie enced previo ously. 3. ““Rok Props” greatly reduce the amouunt of time sp pent on tthe goaf edg ge as oppose ed to the timee it takes to erect e a ““pigsty” or “liink n Lock”. Hydraulic H ennergy is dissip pated ffrom these props p once in nstalled. 4. ““Cans” greattly reduce the e amount of time spent on o the g goaf edge as s opposed to o the time it ta takes to erec ct a ““pigsty” or “liink n Lock”. 5. PUR and Fu ully grouted 8 metre Boween roof bolts cconsolidated d the take-offf face roof in the last few shears w when abutment load beg gan to load u p the face. 6. ““Rok Props” and “Cans” held the imm mediate goaff up better than previous b p occa asions and reeduced the risk r to e employees of o roof falls around the Loongwall supp port b being extrac cted. 7. T The combina ation of all the componennts keeping the face o open, reduciing ventilation and diesell particulate issues i a as well as maximising m the number off machines able to w work on the face.

Photos s

Prevvious Take-o off face, photo o shows timbber chocks fa ailing unde er load. Cans s installed as s a reactive m measure.

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Prevvious Take--off face. Ro ok Props annd mesh modules usedd to retain collapsed c rib b and spray grouted sty yle conssolidation/retention pro oduct.

412 Longwall Ta ake-off face utilizing u “Husska” style me esh, Self drilling “Hilti”” bolts, Hydraulic “Rok Prrop”s, Ceme ent filled “Can ns”, PUR and d Fully grouted 8 metre B Bowen roof bolts. b

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2010 Nomination 2 ns

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A AIRLY Y-E ENVIR RON NMEN NT Field Nam me Title

Exc cellence and d Innovation ns Data Airlyy Coal Handlin ng Infrastructure Constructtion Innovatio ons

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Airlyy mine has th he opportunitty to be a new w mine for Centtennial coal constructed and developped to industrry best stan dards. Bein ng located in the picturesque Caperteee Valley, the e chal lenge of the site layout, design d and cconstruction was w to prod duce an operrational mine site which hhas minimal impact i on th he surrounding community, environm ment and visu ual intrin nsics of the region. r h the objectiv ve of the Airly y Mine consttruction being g to With have e minimal impacts on the region’s envvironment an nd com mmunity, apprropriate profe essionals weere engaged to desig gn and cons struct the min ne site underr the guidanc ce of the A Airly project team. t Targ gets for the site s design were to constrruct a mine that mini mises offsite e impacts of noise, n stray llight and watter pollu ution whilst at a the same time allowingg the site to be b engi neered for whole w site wa ater catchme nt and 100% % water reusse along with high energy y efficiency oof the coal ha andling infra astructure. Interrnational Env vironment Co onsultants (IE EC) were ap ppointed to de esign the wa ater catchmen nt systems oof the mine site. IEC’ s designs allowed for cle ean and dirtyy water separration acro oss the site which w is graviity fed to the water catchment dam ms. All dirty water w on site is captured in pollution control c dam ms which eventually reporrt to the mainn primary setttlement dam m. From both h the primary settlement ddam and clea an wate er discharge dam, proces ss water for ssite is obtained and then n recaptured and reused as part of a cclose water system s loop p of the site.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

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AN NGU US PL LACE - ENVI E RON NMENT Field Nam me Title

Exc cellence and d Innovation ns Data Rain nwater capture tanks to supply washddown area

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Angu us Place has s historically used potablee water supp plied from m regional cattchment area as to wash ddown site veh hicles. In re ecent years lo ocal water re estrictions haave reduced the avai lability of this s supply. Usin ng a risk base ed frameworrk, it was idenntified that Angus A Placce faced pote ential litigation if the collieery continued d to use pota able water to wash down vehicles. In addition, it was w iden tified that the ere was a sig gnificant costt to the busin ness ulting from pu urchasing wa ater to wash ddown vehicle es. resu o 60,000L rainwater tankss were installed at Duri ng 2009 two northern end d of the works shop roof areea, with gutte ering the n mod dified to captu ure rainwater to be used in the vehicle wash dow wn process. As p part of the de esign, consideration was also given to o dry perio ods. A suitable solution to t ensure a pplentiful supp ply of wate er was to con nstruct a pipe eline from thee underground dew watering netw work to the tanks providingg a top up sy ystem. To ccoincide with safety consiiderations, thhree fire hydrrants have e been fitted to the pipelin ne from the uunderground d dams to th he rain tanks. This clearly y allows an eelevated leve el of fire fightting ability. having a cons stant supply of recycled w water, wash down By h activvities can con ntinue withou ut risk of litigaation and ad dverse publ icity.

How th he solution goes g beyond complian nce

In ad ddition to mittigating the risks associatted with brea aching loca l water restrictions, the scheme enabbles Angus Place P to achi eve ongoing improvemen nts by introduucing sustain nable astructure in to t its currentt operations. The recycling of infra rainw water and mine water in this t fashion iis not a requ uirement of Angus A Place’s license/connsent to operate, how wever is a sus stainable option of addresssing an exis sting proccess. The developed solution s highllights the duee diligence and a proa active approa ach adopted by Angus Pl ace regardin ng ongo oing operatio ons, as well as a best practtice to complly with loca l legislation.

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over

a is utilise ed by variouss personnel across a The washdown area hifts. As the e scheme has s fully replacced the potab ble all sh supp ply, all users of the wash down area bbenefit from the sche eme.

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a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Addiitionally, the option of adding fire hyd rants was pu ut forw ward by Outby ye Services, highlighting the level of mine site integration during d the design stage.

Benefit

en the curren nt drought conditions andd Angus Plac ce’s Give proxximity to the township t of Lidsdale L (whho also have to adhe ere to the res strictions) the e consequennces associa ated with adverse reg gional publicitty are considderable. Furth hermore, the e financial pe enalties assoociated with such s legisslation for corporations arre significantt.

Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Man ny existing op perations and d residential dwellings us se capttured rainwatter for variou us purposes ssuch as irrigation and potable cons sumption. Mines M have thhe added adva antage of sec curing water resources dduring drough ht perio ods by using mine water to top up resserves. Thiss solution has s considerable applicabiliity across a diverse d rang ge of industries. Essentia ally, any induustry which has h consstructed large e roof area buildings b couuld benefit fro om captturing rainwa ater and using it in operattional proces sses. Speccifically in terms of mining, all operatiions wash do own vehi cles as part of their daily activities. T To that end, the t use of re ecycled rainw water or mine e water is an obvious sou urce whicch can be used sustainab bly.

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A ANGU US PLAC P CE – HEA ALTH H AN ND SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data Pum mp Suction Arial

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent

ook Assess & Plan (SLAP P) training se ession Duri ng a Stop Lo hift employee es, injury staatistics were with afternoon sh ncial years A AI & II report.. high lighted from the last finan at we had se everal injuriess from strains & Theyy showed tha spra ains to the ba ack while employees were re attempting g to remo ove pump su uctions from mud & Coal fines. The identified ris sk was injury due to the aavailability orr nonavai lability of equ uipment to break the sucction from the e mud whe n removing/c cleaning the pump suctioon strainer. (Sho ovels tend to disappear) Find ding the locattion of the ac ctual strainerr when it is subm merged was also identifie ed as an addditional risk.

An a afternoon shiift employee in Outbye seervices who interrmittently has s to check pu umps and puump suctions s sugg gested that th here should be somethinng attached to the sucttion strainers s to identify th heir location and that this s could be u used to free the t strainer frrom any sucttion in the mud. A pro rototype was developed utilizing u a rib dowel & reflector strip p that we currrently use forr other appliccations and this t was attached to a base plate e that is weld ed to the strainer. A tria al has proved to be very successful w with the pump sucttions able to be identified from a distaance and by using the d dowel as a le ever the sucttion is easily released negating the n need to lift an nd pull on the suction hosse.

Initia ally it was envisaged thatt the Arial waas to be used d for findi ng the subm merged Strain ner and releaasing the suc ction but a after initial triials it is now to be utilizedd along trave elling road ds to preventt the strainers s from beingg run over by passsing machine es. Storres figures sh how that we currently usee approx 121 1 strai ners per yea ar or 2.3 strainers per weeek. With h the introduc ction of the Pump P Suctionn Arial we arre mon nitoring to see e if this figure e is reduced . vices superin ntendant andd the pumping The Outbye Serv e high praise for the emp loyee who fo ound coorrdinator have this ssolution to th he highlighted risk and haave contacte ed the loca l supplier of the strainers s to have the m modified before b delivvery.

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(that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

eduction in innjuries in rela ation to The major beneffit will be a re dling pump suction s strain ners. hand Othe er benefits will w be a reduc ction in damaage to these strai ners, a more e efficient pumping syste m and the re esulting costt savings to the Company y.

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A ANGU US PLAC P CE – HEA ALTH H AN ND SA AFET TY Field Nam me

Exc cellence and d Innovation ns Data

Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

The Rib Reflecto or An O Outbye Services employe ee identified the need to posittion direction n indicating reflectors in tthe tertiary es scape route e without the e need of a la adder or EW WP. Dire ctional reflec ctors are use ed to assist inn the evacua ation of the m mine when utilizing u the te ertiary escappe route – gre een head ding out – red heading in. The identified ris sks were the use of laddeers in an isola ated and dusty enviro onment underground and the logistica al prob blems of orga anizing an LH HD with EWP P to work in the t returrns under the e same envirronmental coonditions to replace r or cl ean reflectorrs.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly d into how the site operattes) integrated

dentified the fact f that the ribs are mes shed The employee id and that this cou uld be utilized d to attach thhe reflectors to inste ead of attach hing them to the t roof. The solution is to o attach a fle exible reflecti ve strip to th he rib messh so that it is s easily acce essible for cleeaning or rep placing. The reflective strrip is flexible so it is attacched by twistting the strip p and affixing to the rib mesh so only rred can be seen s lookking inbye and green look king Outbye.

The solution is as a simple as it sounds andd negates th he need to usse ladders orr organize machines for E EWP’s. Therre is conside erable reduction in dust m make making for a heal thier work en nvironment.

u alongg parts of the The reflectors arre currently utilized m and aree fully indors sed by Tertiiary escape route of the mine the m mines HSEC C committee. Othe er areas of th he mine are being b considdered for the impl ementation of o the reflectors.

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Any site that is utilizing u rib mesh to stabiliize the rib lin ne can inco rporate the reflectors r into o the mines ssystems.

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A ANGU US PLAC P CE – HEA ALTH H AN ND SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data Mod dified “Spyder” Longwall Face F Drill Rigg

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

P e (PUR) into longwall fac ces to The injection of Polyurethane ken strata is a routine opeeration in lon ngwall conssolidate brok mine es around Au ustralia. The e drilling of hooles in the lo ongwall face e / roof is nec cessary to fac cilitate injectiion of PUR. Currrent practice involves use e of MBS / LF FD drill rigs which w requ uire the drillin ng offsider to stand on thee unprotecte ed face side of the AFC to t change drrill steels (adjjacent to inherently unsttable roof con nditions) – se ee Figure 1 bbelow. Therre have been n a number of o strata relatted injuries aand even fata alities in th e Australian underground coal miningg industry to perssonnel workin ng on the AF FC. This issuue was identified in HSE EC risk asses ssments, butt no “off the sshelf” equipm ment was available to mitigate the risk of injuryy from this ha azard. Figu ure 2 below shows s how a roof fall on tthe longwall face can completely fill f the AFC with w stone – tthe position where w the d drilling offsider would stand to changee drill steels whilst ng PUR hole drillin es. An in nvestigation was conducted with sup pliers of drilling equi pment for op ptions. Initially it was prooposed that the Ram mbor rigs use ed for the longwall face ribb boltup be mod dified to suit the t drilling off PUR holes. Alminco ha ad a prod duct which ha ad been used d for longwa ll face drilling g – the “Spyyder”. In the form which was w suppliedd for the initia al trial, the rrig was still mounted m in a position whiich required the drillin ng offsider to o stand on th he AFC to chhange drill ste eels, how wever, the pottential for mo odification waas identified.. owing the inittial trial, the rig mountingg position was Follo shiftted to allow drill d steels to be changed from behind d the AFC C spill tray. In n addition, th he rig was maade more mo odular by e enabling the drill d motor to be removedd to reduce weight w for ccarrying on to o the longwall face. The drill collaring g arran ngement, the e rotation join nt and the AF FC mounting g braccket were als so modified to o better suit tthe task of exte ension drilling g of PUR holes. Figure 3 below show ws the “Spyyder” at the underground u trial. Currrently the pra actice of work king on the A AFC for the purpose p of drrilling PUR holes is still widespread. w A At Centennia al us Place the Angu e hazards ass sociated withh this practice have been n recognised d, and new equipment haas been purchased to m mitigate the ris sk by changing the requi red operating posittions of pers sonnel from a hazardous position (on the walkway alo AFC C) to a relativ vely safe pos sition (in the w ong the face e behind the AFC A spill tray y).

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

( modified) could becoome “best pra actice� Thiss equipment (as UR hole drillin ng in longwalll faces throu ughout in th e field of PU c significantly reducee the probability of the i ndustry. It could dents related d to personnel working onn the longwa all AFC. accid

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AW WAB BA - E ENVIRON NME ENT Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

Exc cellence and d Innovation ns Data Pollution Control C Impro ovements at A Awaba Colliery

C Dam (PCD) disccharged on several The Pollution Control asions with total t suspend ded solids (T TSS) above licence occa crite eria. There were w no monitoring or alaarm systems s on the PCD D to warn or inform i site personnel of tthe dam leve el. Site personnel were w not aw ware of the im mportance of o water man nagement an nd preventing g turbid watter discharge es from site. aba Colliery commissione c ed GHD to uundertake a study s to Awa dete ermine the capacity of the PCD, and the Average A urrence Interval (ARI) ra Recu ainfall event which would d result in th e PCD disch harging. Afterr discovering g that the PC CD dischargged in a 1 in n 1 year rainffall event, th he dam was s de-silted uusing a long-reach exca avator. The dam d was the en pumped ddown furtherr, and a bobccat with a bu ucket was us sed to removve the sediment that rema ained in the dam. d A se econdary pon ntoon pump was installedd which could pump the w water down an extra 60c cm, which inccreased the volume of tthe dam. A new pip pework systtem was installed unde erground wh hich allowed the water frrom the PCD D to be pum mped to old workings w for settling s time. The float valves s were chang ged to allow w for the dam m to be pum mped lower, and a level sensor monitooring installed d which givess real time monitoring m off the dam levvel (recorded d on the sitess monitoring g system - CITECT. Thhe CITECT system alarm ms when th he level is close to thee spillway and a the pum mps can be ch hecked to en nsure they arre both workiing. Apprroval from th he relevant regulatory r aggencies is currently c bein g sought to o expand the PCD too store the run-off gene erated by a 1 in 10 year ARI A 24 hour storm event.

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How th he solution goes g beyond complian nce

A W Water Management Failure Modes annd Effects Analysis A EA) risk ass (FME sessment wa as completedd by Awaba Colliery to i dentify the major risks associateed with the e water man nagement sy ystem at Awaba A Collieery. A majjor risk iden tified during the risk assessment waas that the PC CD had insuffficient capacity. A sttudy on the e PCD was s completedd to find ou ut what cond ditions Awaba had onsite includinng: dam ca apacity, pum mping capacitty, catchment area and raainfall. Awa aba then exp plored all possible solutioons to upgra ade the syste em in place to determine e what Awabba could do without requ uiring approv val. Awa aba then identified furthe er improvem ments to the current syste em required to meet env vironmental sstandards. Approval A from m the releva ant regulatorry agencies is currently y being soug ght to expand the PCD to o store the ru run-off generrated by a 1 i n 10 year AR RI 24 hour sttorm event.

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

p Site personnel monitored the dam leevel and pumping me to keep the dam level to a minimuum. regim The Awaba Under-Manage ers track tthe dam le evel on CITE ECT when itt rains and inform the oother staff members whe n the level is s increasing towards t the sspillway. The alarm systtem in CITE ECT ensuress that the surface com mpetent perso on checks to o make sure that the pum mps are workking when it is raining. The importance of water management onnsite has become a el. There hhave not be een any key factor to siite personne disch harges from the PCD sin nce this projeect commenc ced. The system is in ntegrated into o Awaba’s allarm system so that it is n not one pers sons respons sibility. Mon nitoring allow ws for records s to be kept oof dam levels s and to iden tify when dis scharge occu urs.

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AW WAB BA – HEA ALTH H AN ND SA AFETY Field Nam me Title

Exc cellence and d Innovation ns Data

Awaaba Colliery – Fitness forr AFTER Woork

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Like most mining operation ns in the Lakke Macquarie regi on, the ope eration is ma anaging an n ageing e current average age of the work kforce workkforce. The is 50 0 years with a median age a of 48 ye ears. Prior to 2008 8, injury management and health initiatives at a Awa aba Colliery y had not been strateg gic and in th he mosst part were e reactionarry. For sseveral yea ars, Awaba Colliery C in te erms of its re ecord of in njuries and return r to wo ork outcome es had rema ained quit e stable but at an unsu ustainable le evel. The ncern amongst the mine managem ment was th hat con en the agein ng of the workforce an nd expected d give worssening of ge eneral health and fitne ess, consiste ent with pop pulation tren nds across Australia, A Aw waba Collie ery anti cipated de eterioration in i its workerrs compensation ook and a concomitan c nt decline in n workforce e outlo hea alth and fitne ess. It was anticipated a d that these issues wou uld at some point impa act on produ uction.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

ange of targ geted health and safetty interventions A ra were e planned and a introdu uced. The h health outco omes Awa aba Colliery y set out to achieve a as part of this health initia ative included: ed sprains and strains in ncidents Reduce Enhanc ced return to o work outc comes Greaterr worker gen neral health h and fitness as measured by objec ctive marke ers such as weight w d aerobic fittness loss and Improve ements to workers w com mpensation outlook k

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How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Follo owing on fro om the service trial, Aw waba in parttnership with h Ethos Hea alth has sinc ce delivered d on a num mber of othe er strategic workforce h health and lifesttyle initiative es including g: 1. Annual PSA testing 2 2. Diet and d weight losss informatio on and challenges 3 a Lifestyle e screening g assessmen nts 3. Health and 4 4. Diet and d weight losss informatio on and challenges 5 5. Flexibilitty and functional healtth 6 6. Manual Handling riisk identifica ation and ta ask specific c training 7 7. Rapid re esponse inju ury manage ement 8 8. Nutrition n assessmen nts and plan nning 9 9. Assisting g employee es to Quit sm moking.

hermore, in order to promote and d maintain th he Furth mom mentum of the program m, keeping health, safe ety and d lifestyle a priority p for th he colliery, m manageme ent in colla aboration with w Ethos He ealth have undertaken n the follo owing activities Publishe ed and disp played inform mation postters regardin ng a range of health a and lifestyle topics Produce ed a stretch hing DVD sh hown on loo op on a flat sc creen televission in the m muster area. Printed and distribu uted quarte erly topical health h and lifestyle information ealth has atttended saffety and he ealth Ethos He briefings to answerr questions a and discuss the m with the colliery c HSEC C committe ee program Atte endance att muster talk ks and unde erground vissits to prod duction and d outbye arreas by the health proffessionals to o be availab ble to answe er questionss and mai ntain a ‘pre esence’ on the site

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

In regarrds to speciffic and mea asurable outcom mes, below iss an outline e of results against the targ geted objec ctives as thiss initiative was w comme enced. a) Red duced sprain ns and strain ns incidentss – Sinc ce the introd duction of th his health in nitiative at Awaba A Colliery, a 40% rreduction in n spra ains and stra ains inciden ce has bee en realised. Additionally, asso ociated with h the 8 project for the oil dru m handle, no n 2008 injurries have be een sustaine ed whilst und dertaking oil drum hand dling related d tasks b) Greater workerr general he ealth and fittness m by objective e markers su uch as as measured weig ght loss – Th he weight lo oss challeng ge and actiivities regard ding diet an nd nutrition have seen n a weight loss l average e across the e pit of 3kg with the sin ngle largest weight loss of 20kg g achieved by one wo orker. This weight w loss has been sustained ovver 12 months. This weigh loss outcome o fo or Awaba Colliery C is in contrast to a national average where w workers are gaining weigh ht by 1kg pe er year ensation savvings - With c) Worrkers compe con nsideration to the avera age cost ($1 13,288) of a musculoske eletal claim m in the NSW W Coal Indu ustry (DPI, Prrofile of Man nual Handling and d Musculoskeletal Claim ms in the NSW Coa al Industry, July J 2008). B By treating inured i works onsite av voiding up to o 20 injuriess at Awa aba Colliery y proceedin ng to claim in 2009 9, a cost sav ving upward rds of $260,0 000 has bee en achieved d. d) PSA testing resu ults – since a annual PSA enced, 8 wo orkers have been testiing comme iden ntified and referred r ontto their loca al GP for further f invesstigation e) Ado option at oth her sites – M Myuna has ado opted the concept in 22010

CHA ARBON - ENV VIRO ONM MENT T Field Nam me

Exc cellence and d Innovation ns Data

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Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Conttinuous Imprrovement of a Water Man nagement Sy ystem

Disccharge of watter that exceeds pollutionn limits into the catc hment down nstream of the mine is thee single biggest envi ronmental ris sk for Charbon and mostt CEY mines. The pollution con ntrol structures and Wateer Management Systtems (WMS) of the mine need to be cconstantly mon nitored and im mproved to ensure e that thhey have the e capa acity and ability to lower the t risk of poolluted waterr harge. disch ng available resources r an nd modern teechnology, th he mine Usin shou uld be able to o continuous sly improve itts WMS in orrder to lowe er risk and make the task ks associatedd with WMS easier e and less time consuming. Ex xamples of thhese improve ements inclu ude: 

Real time water quallity and wateer level monittoring with bac ck to base an nd personal aalarm capacity.

Innovativ ve design of dams and d rainage to ta ake advantag ge of naturall features an d overcome geomorp pholgical con nstraints.

Integrating landscape features suuch as consttructed wetlands s and riparian corridors innto the syste ems

Using wa ater chemistry to enable problems wiith pollutantts to be ameliorated.

Using re enewable ene ergy sourcess to power pumping g/siphon systtems and othher power ne eeds in relatively y remote loca ations.

Therre is no real legislative re equirement too establish in ndustry bestt practice sys stems to man nage a site’ss water, but itt sure makkes sense.

portant and iintegral part of the The WMS of a site is and imp nagement of the surface environment e t which exten nds to man the l ife of the min ne and beyond.

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

The peace of mind that come es from know wing that we are doin g all we can to lower ourr risk of pollu ting downstrream wate ers.

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CHA ARB BON – HE EALT TH AND A S SAFETY Y Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how olution mitiga ated the risk the so

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Exc cellence and d Innovation ns Data Mak king Breakerr Line Roof Supports Fiit For Purpo ose Prob blems encountered with the t Breaker LLine Supportts (BLS S) include; th he use of staple-lock hosees, isolation issues with supporting the t canopy and a fluid undeer pressure, roof boltss have been known to bre eak and fly innto the work area, main ntenance pro ocesses like slinging and easy access s to com mponents werre not provided for. ough consultation, persev verance, goood design wo ork Thro man ny solutions to t the problem ms were idenntified. Using g the “Hie rarchy of Co ontrols” the sttaple-lock hooses were subsstituted for JIIC hoses, rub bber belt loo ps were added to the ffront of the canopy as a barrier b to hel p reduce the e brea aking roof bolts from ente ering the worrk area, the electtrical panels were redesigned to fit innside the BLS S to allow w repairs to be b conducted d much saferr than the alterrnative, and accessories a like extra ruddd links and safety bracckets were installed to pro ovide extra ssecurity to iso olate the e energy sourc ces for repairrs and mainte tenance. Cha rbon Mine ha ave been using Breaker line Supports in a high ly competent manner forr years. Charrbon is strivin ng for a step p change in safety s that go oes beyond ccompliance, to t provvide equipme ent that is ultiimately “Fit F For Purpose””. The fitterrs and operators construc ctively contri buted to solv ving the prob blems that we ere foreseen on the neweer style Brea aker Line e Supports. Charbon C prov vided the oveerhauling com mpany with valuable info ormation from m our years of experienc ce and we g got them to go g the extra mile. m

Conssultation and d ownership from the worrkforce ensured succcess for the BLS B overhau ul project. Th e BLS’s have been in usse for some time t and the innovations are being us sed by the w workforce.

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Som me of the idea as have not yet y been adoopted by othe er mine es with BLS because unffortunately thhe bigger cha anges need d to be conducted at the overhaul staage or during ga shuttdown period d. Some of th he more obvioous ideas ha ave been n adopted ind dustry wide on o BLS.

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CLA AREN NCE - EN NVIRO ONM MENT T Field Nam me Title

Exc cellence and d Innovation ns Data Bestt practice Wa ater Management

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

w released through LD D02 was a concern c The quality of water Clarence cou uld not meett compliancee the Environ nmental as C Prottection Licen nce without the t operationn of the site e Water atment Plant. Trea The aesthetic qu uality of the water is low w because of o solids run-o off. The sam me water is used for pota ble water (sh howers, wash h-down bay and underground). menced acttively investtigating the water The site comm nagement sy ystem at Clarence. Thee investigation has man inclu uded identify ying water flo ow paths, annd sub comp ponents of th he system. The T investigation identifieed the opporttunity to only release clea an water from m LD02. Stag ge 1 of the water w manage ement syste m investigattion and upgrrade is pres sented in this submisssion. Stage 1 was iden tified follow wing discuss sions betweeen site perrsonnel. The components s of Stage 1 are: 1. Upgrade e of the pit top t grit trap facilities to remove the entry y of solids frrom the wasshdown bay into the water management system. A cooncrete wall across the top of o the girt tra ap will preveent large solids, and grated areas a will allo ow water to ppass through h. Solids will then be collected d from the exxisting bunke er. 2 2. Pumping g of water fro om the pit toop grit trap to o CHPP B Thicke ener to re-use the water ((and reduce volume of dirty water w entering the Polishiing Lagoon).. 3 3. Commis ssioning of gravity fed pipeline fro om the Polishing g Lagoon to the Leachaate No. 2 Da am. The Leachate e No. 2 Dam m discharges water to the e gravity fed Lea achate bore ehole, placiing water in the undergro ound dam. All A water froom undergro ound is treated in i the Waterr Treatment Plant prior to being released d to LD02. The grav vity fed pipe eline from thee Polishing Lagoon is at a de epth to provide a holdingg basin. The holding basin ensures that no dirty w water is disc charged through LD02 (excep pt extreme raainfall events s).

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How th he solution goes g beyond complian nce

Clarrence is not required to treat all waater on site prior to disch harge throug gh LD02. Rele ease of only treated water off site ennsure the qu uality of wate er released to the Wollangambe R River, transfe erred to Farm mers Creek catchment and utilisedd on site is of the high est quality. The improvemen nt of water quality releaseed will also improve the quality of water w used by b the workfforce for sho owering afterr shift.

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

on to site water w manag ement over site is The investigatio en by a team m. The invesstigation is ongoing o bein g undertake t documen ntation of finddings to ensure that and will involve the ommunicated d appropriateely, and recorrded for inforrmation is co futurre reference.. Duri ng the waterr manageme ent review thhe site requirrements for meeting compliance with licences and development conssents was discussed. d This T strategyy aims at ensuring e Clarrence is awa are of its legal responsibbility so that actions unde ertaken are not n in contradiction to theese. The aim m is that actio ons for en nsuring bes st practice consider licence requ uirements. The options inve estigated for the water m managementt review at C Clarence arre engineeriing actions.. The actio ons are passsive (do not n require ongoing m maintenance e). For exam mple, the info ormal reason ning for the ddecommissio oning of the Clarence oil and solids separator oon the Pit Top T Grit Trap p was the hig gh maintenan nce schedulee.

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

ater management has beeen undertak ken as a The review of wa team m. The review required d the buy iin of all le evels of man nagement forr the investig gation and ddecision making for the upgrade of Phase 1. The T sharing of this information acro oss the mana agement team has starteed the ownership of the w water manag gement syste em by all tea m members. The mining ope eration has operated foor over twen nty five yearrs where the impact of no ot recording tthe decision making proccess through h risk mana agement hass impacted on our curre ent understtanding of the site w water management proccess. The recording of o informatioon as this water man nagement prroject progre esses and ccomponents of the syste em are ide entified ensu ures that fuuture management decissions will be made on ac ccurate inform mation. The solution ensures that through onlyy clean wate er being ased we are e positively impacting o n the water quality relea that is discharged (to the Wollanggambe Rive er and transsferred to Fa armers Creek k catchment)).

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M MAND DALONG G - ENVIR RONMEN NT Field Nam me Title

Exc cellence and d Innovation ns Data Apprrovals Comp pliance Datab base

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Mandalong Technical T Se ervices deparrtment recog gnised  M tthe need to more m effectiv vely manage over 800 cconditions off mining and environmenttal approvals s.  E Existing systtems were un nable to provvide effective e m management of the number of approvval condition ns and tto ensure and document compliance..  F Failure to comply with the ese approvaal conditions e exposes the company an nd individualss legally and may p potentially lead to busine ess interruptioon. The solution was to deve elop a databaase with exis sting  T ssoftware (MS S Access) tha at was simplle to use and d could b be developed d to suit the needs of Ceentennial.  T The initial da atabase was designed byy Mandalong Mine, w with final dev velopment co omplied by F Forsythes IT.  T The Complia ance databas se provides a register of mining a and environm mental appro ovals or projeects.  R Register of conditions c witth assigned aactions.  A Actions are scheduled s by y date or longgwall chainage and a assigned to the t person re esponsible.  L Link associated documen nts to approvvals, conditio ons and a actions eg co opy of approval, licence, report.  P Personalised d view with windows w logoon and security llevels. User friendly y front menu to access th e various sections  U o of the databa ase.  V View overdue or pending g Actions withh filter and so ort ffacilities.  E Email actions s to person responsible r ffor a selected d n notification period. p  F Facility to rea adily query, collate c and aaudit data  R Reporting – approvals, a co onditions, acctions, person in P PDF or Exce el format. The compliance database is used at Mandalong Mine M  T ffor collating, scheduling and a maintainning all condiitions of m mining and environmenta e al approvals as wells as rrequirements s of the Mand dalong Businness Manage ement F Framework and a Coal Min ne Health andd Safety Actt.  D Departments s and individu uals can mannage conditio ons rrequirements s in a secure e and centraliised registerr.

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

The compliance database allows a seecure record d and  T d documented history of ap pprovals at thhe site.  P Provides dettailed informa ation for integgration of ne ew staff.  A Approvals re equirements are a assignedd to the relev vant p persons and managed on n a daily bassis.  A Approvals ca an be instanttly audited foor compliance e.  T The Approva als Compliance databasee has been adopted b by the majority of Centen nnial operatioons and man naged b by the site’s Environmental Coordinattor.  IInterest from m other mining g companiess.

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M MAN NDAL LONG G – HEA H ALTH H AND D SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data Subssidence Ana alysis using Airborne A Laseer Scanning

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly

Mandalong Mine M uses an n innovative m mine design to  M p provide reduced levels off subsidencee and impacts to the M Mandalong Valley V floodplain, propertyy and enviro onment.  T The mine has strict Deve elopment Connsent conditions rrelating to su ubsidence im mpacts – propperty, flood and a lland-use.  H Has extensiv ve subsidenc ce monitoringg requiremen nts to d determine the level of subsidence an d prove the mine d design. There was no av vailable subssidence information tto validate su ubsidence prrediction moddel.  P Provide subs sidence monitoring wheree land acces ss was p prohibited eg g private prop perty and steeep terrain.

Airborne lase er scanning (ALS) ( was thhe preferred  A ttechnology to o provide pre e-mining terrrain model att M Mandalong due d to the diffficult terrain (Watagan M Mountains, tree cover). ALS A has the ability to penetrate tthe gaps in the vegetation canopy.  IInitial ALS te errain model used for moddel flood leve els.  M Mandalong Mine M theorise ed that subsiidence could d be d derived by su ubtracting su ubsequent ALLS data from m the iinitial ALS da ata set. ALS data could be compared and verrified againstt the  A e existing conv ventional monitoring.  A ALS could be e used to me easure low leevels of subs sidence o over the entire mining are ea, providingg valuable da ata to a assist in the validation the mine desiggn, calibration of tthe subsiden nce prediction n model and compliance.  A ALS provides s the ability to t quantitativvely demonsttrate tthe magnitud de of subside ence and othher environmental cchanges to the whole of the t mining aarea eg floodplain a and wetlands s.  P Provides sub bsidence data in addition to the exten nsive ssubsidence monitoring m program, whicch currently e extends overr 40km of mo onitoring linees. ALS is acquired at approximately twoo year interva als to  A ssupplement conventiona c l subsidencee monitoring.  IIndependentt validation of subsidencee results and ssubsidence model. m  IIncorporated d in the generation of floood modeling and a

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integrated d into how the site operattes)

a assessment of the Mandalong Valleyy  F Flood modeling and asse essment is reequired in the e SMP p process and for complian nce with Devvelopment Co onsent C Conditions.

Benefit

Provide subs sidence monitoring and oover the entirre  P m mining area.  P Provide subs sidence monitoring in inaaccessible areas ssuch as priva ate property and wetlandds as well as h hazardous stteep terrain.  R Reduce the quantity q of co onventional m monitoring p providing fina ancial benefits.  A ALS has bee en used to prrovide the terrrain model for f the M Mandalong South S Project.

Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

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M MAN NDAL LONG G – HEA H ALTH H AND D SA AFET TY Field Nam me Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Exc cellence and d Innovation ns Data IIMPLEMENTIING THE AUT TO-CUT FEATTURE ON ABM M25 CONTINUOUS MINERSS

The floor horizon n in developm ment districtss has been a major safe ety and opera ational issue at the mine ddue to matte ers relatting to the difffering cutting techniquess of operatorrs with the A ABM25 contiinuous minerrs.

Rem move the hum man factor co omponent froom the proce ess of cutti ng the floor horizon h and allow technoology to bette er man nage the proc cess. Whille operator trraining, procedures and ccrew talks fa ailed to delivver consisten ncy in floor horizon controol, the additio on of the a auto-cut systtem provides s for far greatter compliance. It de elivers benefits in safety improvementt, a more con nsistent flow of coal from m the C/M, red duced damaage to other mine m macchinery and an a improved work area w when conductting tasks ks such as be elt extensions s. M M Mine Change The OHS Ten Hurdles and Mandalong nagement pro ocesses were followed prrior to the Man intro oduction of th he auto-cut system. An o operational risk assessme ent was condducted, invollving operrator, engine eering and OE EM represenntatives to identify any risks and ha azards associated with thee introductio on of the ssystem and to t implementt adequate ccontrols to ma anage iden tified issues. Initia ally, one crew w in MG10 was w chosen too be involved d in triali ng and testin ng the system m – the systeem was enab bled at the sstart of the shift, then disabled at the end of the shift. Thiss process was followed un ntil confidencce was high that the ssystem work ked as it shou uld and the ccrew using it were seen n as ‘champions’ of the system. Onc e fully proven, the system m was rolled out to all cre ews in MG1 10 and then the t system was w progresssively fitted to o the othe er ABM25 C/M M’s at the mine.

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

h provided d multiple bennefits, including: Thiss innovation has o Reduced d number of S, T, F and ‘‘jarring’ injuries in developm ment districts s; o Reductio on in equipm ment damagee (e.g. S/C’s & man transporrts); o Smoothe er C/M opera ation (shearinng up/down at a set rate) and d more consistent flow off coal; o Cutter and Loader motor m current levels have been ‘smoothe ed out’.

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M MANNER RING G - EN NVIR RONM MEN NT Field Nam me Title

Exc cellence and d Innovation ns Data New wvale Gas Le eak

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how olution mitiga ated the risk the so

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

A ga as leak was detected d at th he Newvale site by a local jogg er when they y noticed the e ground bubbbling on a wet w and rainyy day. The le eak was asse essed by ruli ng out the so ource of th he leak. Initia ally it was ass sumed that a crack in the e pipe was the cause but after ventiing both end s and pigging the line tthe leak continued throug gh the surfacce which led to the assu umption that the leak was s coming from m the Newva ale drift locatted directly below b the pip pe line. s is de etermined noo works have e been Untill an agreed solution unde ertaken to fix x the leak oth her than the eerection of a fence whicch was determined from a RA to minim mize the cha ance of sparrks within the e area. Possiible solutionss to fix the le eak wou ld include reconnecting the gas line tto the power station to re educe the pre essure of the e methane inn the workings, ventting to the atm mosphere which would ccreate a gree enhouse issu ue and requirre ongoing m monitoring or flaring whicch would require approva al and consennt modificatio ons to do sso. The gas plant go oes beyond compliance c aas it gives Man nnering a way y of utilising the gas for eelectricity gene eration at the e power station which alloows a rebate e for the collie ery. This pro ocess of utilis sing the gas iis far more bene eficial for the e environmen nt than the otther solutions s of allow wing it to leak k under natural conditionns or flaring. ated as yet. No ssolution has been integra

on of this gass leak to the The benefit of the identificatio mpany outline es the importa ance of sealiing and monitoring com ecommission ned areas as s to avoid furt rther liabilities s such of de as w what has hap ppened at Ne ewvale.

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MYUN NA – HEA ALTH H AN ND SA AFET TY Field Nam me Title

Exc cellence and d Innovation ns Data CAB BADOM

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly d into how the site operattes) integrated

BA suit twin cylinders c cou uld be misaliggned causing g loss CAB of prressure by damage to O--ring In evvent of an em mergency inc cident CABA A suits would have no a air to supply for f emergenc cy evacuatioon of personn nel

p developed a coost effect solution to Myu na Colliery personnel uit damage and a consequuent loss of air a prevvent CABA su presssure.

The CABADOM not only kee eps the CABA A bottles spa aced corre ectly but also o protects the e externals oof the bottle from f accid dental dama age and incre eases visibilitty of the suit.

The fitting of the CABADOM is part of thee collieries erground sta andard. unde

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

BA suits are now n widely used u in the N NSW mining CAB indu stry. CABA cylinders c are e carbon fibree composite and any superficial damage can result r in the ccylinders beiing cond demned. The e CABADOM M is also veryy straight forw ward to fit.

NEW WSTAN - ENV VIRO ONM MENT T Field Nam me

Exc cellence and d Innovation ns Data

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Title Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

A Cultural Spaace for Biraban n Public Schoool (West Toro onto)

estock were accessing a wetland andd creek syste em and Live wa aste dumping g was occurrring at the reaar of the sch hool at Wesst Toronto. This T had resu ulted in the w wetland to becoming sign nificantly deg graded, resulting in a redduction in the e water quallity of the we etland / creek k system (whhich flows into o Stony Ck and Lak ke Macquariee).

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

wstan Colliery y provided fin nancial and ppractical assistance New with the development of an educational e sspace in the wetla and area beh hind the Bira aban Public S School as pa art of a colla aborative app proach to the e addressing the problem m with othe er stakeholde ers including the K2 Bushh Enterprises s (Koo ompahtoo), Hunter H Central Rivers Caatchment Man nagement Au uthority and Lakes L Timbeer and Hardw ware. New wstan coordin nated and fun nded the connstruction of a fence arou und the wetla and to keep livestock out and remove ed wastte debris from m the area to o allow the B Biraban Public Scho ool and K2 Bush B Enterprises to regennerate the arrea. Prevventing livesttock from acc cessing the aarea will allow succcessful regen neration to oc ccur and impprove the qua ality of wate er entering Stony S Creek. The school has also a established Aboriginnal storyboarrds in the a area, to prov vide an opporrtunity for thee students to o learn abou ut some of th he cultural stories for the region. The wetla and area now w provides a fantastic ouutdoor classroom in whicch students can c undertak ke environmeental studies.

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Thiss project is an n example off Newstan Coolliery pro-ac ctively seekking to suppo ort and engage with our l ocal community.

art of Newsta an’s Environm ment & Community Thiss project is pa N is seeking to asssist and engage Busiiness Plan. Newstan with local commu unity groups and organissations where e posssible. This may assist with future com mmunity relations for upco oming Newsttan projects.

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Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

wstan personnel have dev veloped relattionships with local New indig genous comm munity group ps, with the W West Toronto o com mmunity and the t Biraban Primary P Schoool as a resu ult of this project. Man ny other mem mbers of the llocal commu unity are n now aware of o this projectt and the suppport Newsta an provvides to its local communities.

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NEW WST TAN – HE EALT TH AND A S SAFETY Y Field Nam me

Exc cellence and d Innovation ns Data

Title

Coa al Storage Bin Cleaning S System

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

blem was persons’ acces ss for internaal bin inspections at Prob the b bottom of the e bin that cou uld expose thhem to falling g ‘hang up’ m material from m the sides off the bin. Thee 2000 tonne e bin is 30 m high and 15m diameterr Convventional cle eaning throug gh the top off the bin could not clea r debris from m the top lid section s leavinng the bin in an afe condition for access or o work on thhe doors due e to the unsa amo ount of materrial hanging from f the rooff area. A rissk assessme ent identified the hazard. Disccussions werre held with bin b cleaning ccompanies on o their abilitty to clean th he bin safely. None of theem had clean ned a bin o of this diame eter before an nd would nott guarantee their t workk. Theiir first method was for people to enterr through the e top of the b bin on a rope e support sys stem, and whhile suspended, hose e the roof are ea of the bin. Theiir second me ethod was to cut a numbeer of holes around the ttop roof section and lowe er a man in a man box susp pended from a crane. Both h of these me ethods still presented riskk to the work kers so the h hierarchy of controls requ uired a betterr solution.

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

n cleaning coontractors it was w Duri ng consultattions with bin y did not have e a simple saafe and effec ctive evid ent that they way of cleaning bin. Rese earch was co onducted into different w ways of hosing the top rroof section of o the bin wh hich led to invvestigating th he posssibility of usin ng an irrigatio on spray sysstem mounte ed upsid de down. (A typical agric cultural sprayy system) her work identified that most Furth m of thesee systems us se gravvity to provide e the hamme er affect and rotate the he ead arou und. The spray head was attached to a lengthh of 1 ¼ wate er pipe and lowered dow wn from the top section of the bin. This was left rrunning for tw wo days whic ch successfuully cleaned the t rema aining debris s from the roo of section of the bin allow wing the rrequired worrk to proceed d without puttting people at a risk of fa alling objects

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How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Thiss system has removed the e need for anny workmen to ente er the bin to conduct c cleaning, there bby removing the t workking at heights and confin ned space isssues. The sy ystem wentt beyond a compliant, c ho owever, riskyy previous strrategy for th he bin cleaniing task.

d The bin will now be able to be cleaned att each shut down or maintenannce to the low wer provviding a safe work area fo secttion of the bin ns and is parrt of the new procedure. Thiss will also rem move the deb bris that havee been causiing corro osion to the bin extending it’s maintennance requ uirements

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

his system is that it is sim mple to set up p and The benefit on th ed and will bee able to be fitted operrate, can be regularly use to m most coal bins s. The main benefitt is that it rem moves peopl e for dangerrous area as and difficu ult jobs

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S SPRINGV VALE E - EN NVIR RONMEN NT Field Nam me Title

Exc cellence and d Innovation ns Data Enviironmental Datalogger D Alerts A – Daily SMS Update es

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d n at the site - over continuity off the solution a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes) Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

Protection Licence Non--compliance with Environmental P (EPL L) to monitorr and record environmenttal data at Licenced Disccharge Points (LDP). Environm mental Coordinator iden tified deficie encies in the e system (i.ee. manual re ecording of d data) and so ought extern nal advice tto identify possible p soluttions. High level of risk k if data waas not electrronically reco orded on a daily d (24hr) basis (e.g. non-complia ance for each h day data was w not reco orded). Failuure to electrronically log d data on a daily basis att LDP001 reesulted in 71 18 days (betw ween 2005 & 2006) of non-compliaances at Sprringvale Coa l. enspan sup pplied a dattalogger andd daily SMS alert Gree syste em. Data is logged using g a Campbel l’s 8000 data alogger. Data a is then sen nt to the Enviironmental C Coordinator’s s mobile phon ne everyday y at 8:00am, along withh the battery y (volts) leve l. If an SMS is not receiv ved by the nnext day Gre eenspan is co ontacted and d the issue investigatedd, resulting in n no or mini mal loss of data. d The addition of the daily SM MS alerts alllows site to ensure that the battery y level is sufficient to ensure con ntinuous logg ing, and the e data is also sent to the Environ nmental Coo rdinator on a daily basis, which allow ws for an up--to-date overrview of the water w being discharged d frrom an LDP or bore site (e.g. Bore 6,, LDP006, LD DP001 and S Shaft No.3). ure to electro onically log data d on a daaily basis at LDP001 L Failu resu ulted in 718 8 days (between 2005 & 2006) of o noncom mpliances at Springvale S Coal, C due to the EPL stip pulating e recorded electronically e . Due to a te echnical that data is to be issue e with the installed datalogger, datta was corru upt and d not be re could etrieved, resulting in thee non-compliances. Thiss was deeme ed to be a whole w of busiiness issue, and as such h, a ‘daily SMS alert’ solution waas implemented to ensu ure that it did d not occur again. nificantly red ducing the likelihood oof Springvale Coal Sign reco ording a non--compliance due to data nnot being log gged on a da aily (24hr) ba asis from its s LDP001 annd LDP006, as per the E EPL.

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S SPR RINGV VALE – HEA H LTH AND D AFET TY SA Field Nam me Title

Exc cellence and d Innovation ns Data Und erground Arc c Fault Conta ained Switchhboard.

Innovation title Id dentified Prroblem What, who o identified th he problem, how h the problem m was assesssed, what wa as the identifie ed risk assocciated with the problem m

Solutio on What, how the solution came about,, how the so olution mitiga ated the risk

How th he solution goes g beyond complian nce

How the ssolution is inttegrated into the business (that is, demonstrated d continuity off the solution n at the site - over a numberr of years) an nd independe ent (that is, the e solution is beyond just one person driving the outcome - it is truly integrated d into how the site operattes)

Benefit Benefit off the solution n to Centenniial how could o other sites (o or industry) benefit from the ssolution, has it been adop pted elsewherre?

ngineering iddentified the twofold t Site Manager of Electrical En blem, 1) that a risk of arc fault during UG switching g was prob pressent and additionally 2) lig ghtning damaage from ligh htning activvity within the e local area potentially p im mpacted on equi pment/opera ation and em mployee safetty. UG iincidents hig ghlighted the requirementt to look for a safe soluttion. An u underground incident was s the driver ––a catastroph hic failu re of an underground circ cuit breaker. In co onsultation with w potential suppliers AT TF and Sneid der alon g with the DII electrical in nspectorate tthe solution was sort and found. Fit F for purpos se undergrouund arc fault conttained and ra ated switch gear, g an indu stry first. Addiitionally lighttning arrestorrs have beenn fitted, along g with IP ra ated comparttments with remote r closee on the switcchboard. Incre eased inspec ction regime. AS2 2067 audit ca arried out on the switchgeear, all of which are abovve complianc ce. on for UG sw witching goingg forward wh hich Provvide a solutio man nages multiple feeds that that can be readily and safely s switcched betwee en supplies. Postt installation manual hand dling issues are removed d to carryy out the abo ove tasks. The gear integra ates and com mpliments thee pumping sy ystem on ssite which is critical c to min ne operation and a core sight s risk.

mproves safe ety for all sigght personne el, The innovation im ss interruptio on and equippment damag ge prevvents busines throu ughout the mine. m All ssites could be enefit from th he applicationn of this inno ovation. As fa ar as we are aware it has s not been addopted at oth her sitess.

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2012 Nomination 2 ns

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HEALTTH AND SAFETY – – ANGUSS PLACE Title  Innovatiion title Hiltii Bolt Transport Frame  

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.    Angus P Place has recently started d to utilise thhe Hilti boltiing system u using single ppass encapsu ulated rib an nd  roof boltts.  The boltts are self‐drilling and the e resin is insiide the bolt. The boltts are transported througgh the mine  using the QD DS Duck Bill S System.  Each  du uckbill  loaded d  with  Hilti  bolts  wouldd  have  198  bolts,  b 200  do ome  plates  and  200  large  reinforceed  retainerr plates called d “pizza plates”.  The boltts are deliverred to Anguss Place in buundles of 98, the “pizza p plates” in palllets of 100 a and the dom me  plates in n pallets of 980. Each bolt weighs 10kkg and each “pizza plate”” weighs 5kgg.  The bun ndles of boltss are held to ogether with  strapping an nd when thiss strapping i s cut the bolts quickly faall  from forrmation unco ontrolled, th he “pizza plattes” come in n cardboard crates and dduring the loading processs  the operrator has to bend over th he edge of thhe crate to rreach the pla ates. The dom me plates are put into th he  loaded d duckbill and  during transsit they fall bbeside and under the loo ose Hilti boltss making the em difficult tto  access.  A All  of  these  items  are  lo oaded  into  tthe  duckbillss  by  hand  an nd  then  any  remaining  materials  m thaat  come ou ut of the min ne are unload ded by hand,, all of the ab bove handlin ng increases  the risk of in njury. 

Solutio on  What, how the soluttion came ab bout, how thee solution mitigated the risk.  To  overcome  these  manual  han ndling  issuess  a  frame  was  w designed  so  that  thee  bolts  and  plates  can  be  b loaded w with a forklifft.   The fram me is designeed to accom mmodate 2 x  full bundless of bolts loccated side byy side on the e lower fram me  and  then  the  upperr  frame  is  fittted  and  loc ked  in  place e  by  locating g  “sleeve”  sttyle  legs,  locking  pins  an nd  he upper fram me is in placee the “pizza plates” can b be loaded onn while still ssecured in th he  safety cllips. Once th crates.  TThe  dome  plates  p are  sta acked  in  a  sspecifically  design  d chann nel  located  aat  each  end  of  the  uppeer  frame alllowing easyy access. The frame has ffork tine acce ess in both the side and  the ends allo owing it to b be  easily  pllaced  into  a  duckbill  it  also  a has  a  c hannel  on  each  e end  to  carry  the  doome  plates  removing  th he  hazards related to reetrieving the em from besiide or under the bolts in the duckbill..  The fram me is easily rremoved from the duckbbill undergro ound as well,, allowing thhe duckbill to o be taken fo or  alternative tasks while the frame e remains onn the job site e. 

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The strapping which h retains the bolts can rem main in place e until the frame reachess its destinattion.  After  co onsultation  with  w Angus  Place  Tech  Services  De epartment,  Angus  A Placee  mechanical  engineerin ng  Departm ment and GU US contracting supervisorrs the frame design was e engineered bby Alfabs Ma anufacturing.  How thee solution go oes beyond ccompliance:  

 

A JSEA w was carried o out on the usse of the fra me for a triaal period before it was appproved for use to ensurre  that anyy changes needed could b be completeed before the e frame was introduced tto the workforce after th he  introducction of plantt process wa as complete.   This JSEA A identified  that the frame, whilst bbeing carried d inside a du uckbill, was nnot differentt to any otheer  type  of  material  container.  Oth her  types  of  materials  containers  c co onsidered  w were  PUR  pods,  Reliable  /  e Spyder  boltiing  rigs  etc.  The  JSEA  also  identifiedd  that  there  were  several  Endless  belt  splice  equipment,  manual handling and d injury riskss removed inn the loading of the materials by usingg the frame.  After  th he  successful  trial  period d  two  additiional  framess  have  been  manufacturred  which  will  w allow  tw wo  frames tto be undergground in use or transit aand one fram me on surfacce loaded re ady for chan ngeover wheen  a duckbiill with an em mpty frame is presented..  How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  (that is,  the solution site operates).  nsioned Hilti  rib bolts havve proven suuccessful in tthe LW deve elopment Pannel and the second CM iin   The ten the Tand dem unit is ssoon to be fittted with thee Hilti adapte ed drill moto ors.  If the Hiilti rib bolts  are to become the norm mal rib supp port the transport pods w will be utilised across th he  site and potentially o other centen nnial operati ons that utilise the Hilti ssystem.   

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?  The CM  tensioned single pass Hilti rib bolts  are an innovvation in the emselves andd could pote entially be th he  port of the fu uture.  rib supp Issues  w with  the  tran nsportation  and  manua l  handling  of  o these  boltts  have  bee n  addressed d  early  in  th he  process and possiblyy prevented Manual handdling related d injuries.  Currentlly we don’t kknow of anyy other site oor company  utilising the Hilti rib boltts from CM  mounted drill  rigs on tthe first pass.   

 

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HEALTTH AND SAFETY – – CHARB BON  Title  Place ch hanging deveelopment witth mono‐rail  cable handling system.

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.     

Risk of injuryy as a result of manual h andling cables/hoses at the coal facee  Cable damagge – potentia al for incidennt as a resultt of damage. 

Solutio on  What, how the soluttion came ab bout, how thee solution mitigated the risk.  Change  in developm ment processs. Used monno‐rail – prevvious system m adapted too suit multi‐h heading placce  change d developmen nt.  How thee solution go oes beyond ccompliance:   Minimises  the  risk  from  manu ual  handlingg  injuries/rissk  of  cable  damage  in  accordance e  with  healtth  management plan. It is the only Centennial m mine which u uses the mon no‐rail place  change development.  How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  (that is,  the solution site operates).    

Mono‐rail previously use ed at Charboon for a number of years in cut and bbolt developm ment  Reluctance tto change fro om crews  Men have m made the systtem work. 

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?       

No other mines that placce change usse mono‐rail  Potential to introduce th he system intto four other Centennial mines  Lower the exxposure of m musculoskeleetal injuries d during manual handling oof cables and d hoses  Reduction in n cables dam mage.   

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HEALTTH AND SAFETY – – MYUNA  Title  SOTO Saafety Tow Hittch. 

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.    nally,  metho Tradition ods  for  tow wing  shuttlee  cars,  breaaker‐feeders  and  other  heavy  equ uipment  havve  included d:   Draw Bars   Chains   Other tow d devices  or reliability tthat Myuna  required  These teechniques haave not provided the leveel of safety o Towing sshuttle cars has previoussly involved aan operator on the mach hine to steerr and controll braking from m  the shutttle car, whicch put them in a potenttially hazardo ous position,, with restriccted visibilityy and difficu ult  commun nication  Using  ch hains  or  draaw  bars  has  meant  thatt  there  is  litttle  control  of  o the  equippment  beingg  towed,  witth  substanttial damage being caused d to the macchinery and rrib support e en route  Addition nally,  Myunaa has areas o of low hangiing mine serrvices which  had a high  potential to o  be damageed  using  trraditional  to owing  meth hods,  causinng  injury  to  equipmentt  and  persoons  along  with  w businesss  interrup ptions  These  risks  were  highlighted  by  b an  Afternnoon  Shift  Deputy  D and  his  crew,  w who  had  concerns  abou ut  Myuna’ss current tow wing method ds.  The  pro oblem  was  assessed  a by  creating  a  tteam  to  revview  currentt  towing  proocedure  and d  practices  at  a Myuna. Specific atteention paid to low areas aand area und der pipes on the main traavelling road d. 

Solutio on  What, how the soluttion came ab bout, how thee solution mitigated the risk.  A team o of Myuna Co olliery emplo oyees workedd in conjuncction with SO OTO Mining TTechnologiess to develop a  concept for a heavy duty tow hittch  The final design creaated was callled the ‘SOTO O Tow Hitch’  The  SOTTO  Tow  Hitcch  is  a  rigid  articulated  QDS  Load  Haul  Dump  (LHD)  attacchment,  which  allows  fo or  greater control when towing and d has the abiility to push or pull the shuttle car. 

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It  allowss  for  movem ment  in  three  planes,  w ith  vertical  and  a horizontal  control.  It  can  be  locked  in  placce  where n needed. This allows for en nhanced conntrol and the erefore impro oved safety.  The  SOTTO  Safety  Tow  Hitch  grrants  more  control  of  both  b the  bra aking  and  stteering  system  of  toweed  vehicles.   With thee addition o of hydraulic vvalving to thhe brake circcuit, the LHD D driver has  complete co ontrol of botth  the  LHD D  and  shuttlee  car  braking.  The  driveer  of  the  LHD  also  has  control  of  thhe  steering  circuit  of  th he  shuttle ccar from the LHD.  How thee solution go oes beyond ccompliance:   

The SOTO To ow Hitch hass been designned as fit forr purpose 

Traditionallyy the rigid co onstruction w was in the form of draw b bars, it is knoown that cha ains have alsso  been used recently. The SOTO Tow H Hitch is a rigid constructiion, howeve r, it permits movement iin  three planess, with horizo ontal and veertical contro ol, for the eq quipment beiing towed. T This allows fo or  enhanced co ontrol and th herefore impproved safetyy 

Traditionallyy  the  brakin ng  and  steerring  of  the  towed  equipment  was  controlled  solely  by  th he  vehicle doing the towingg and a driveer in the equiipment being g towed 

The  SOTO  Tow  T Hitch  grrants  more  ccomplete  control  of  both h  the  brakinng  and  steering  system  of  o towed  vehiccles.  With  th he  addition  of  hydraulicc  valving  to  the  brake  ccircuit,  the  LHD  L drive  haas  complete co ontrol of botth the LHD a nd shuttle car braking. T The driver off the LHD alsso has contro ol  of the steeriing circuit of the shuttle  car from the e LHD. 

How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  (that is,  the solution site operates).  essment  carried  out  by  the  team  who  w originally  The  SOTTO  Tow  Hitcch  has  had  an  operatio nal  risk  asse identifieed the need ffor improvem ment. A Safee Work Proce edure and trraining syste m has been developed sso  that it caan be used w when needed. It is now w written into Myuna’s tow wing and Co lliery operattional system ms  and is th he preferred method for towing shutttle cars.  Whilst itt is a newly  designed an nd developedd piece of eq quipment it has already  been used sseveral times,  includingg  transportiing  a  newlyy  commissiooned  shuttle e  car  to  the e  Fassifern  Seam  from  the  surfacee.  Currentlly  work  is  beeing  underta aken  to  allow w  the  SOTO Tow  Hitch  to  t be  used  tto  tow  a  wid der  variety  of  o heavy eq quipment. 

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?  

Improved co ontrol of hea avy tow loadss. 

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Improved eaase of manoe euvring the sshuttle cars aand other long loads whiile shunting. 

Damage to m machinery an nd cost of la bour are sign nificantly red duced. 

Increased co ontrol due to o the ability tto control ste eering and b braking from  the LHD: 

Reduces dam mage to macchine, ribs annd pipes/servvices. 

Safer and more reliable towing methhod when co ompared to cchains or draaw bars. 

Allows towin ng a shuttle car to be a oone man ope eration: 

Removes thee need for m man to be on  the shuttle car whilst to owing – elimiinates the rissk of injury 

Eliminates  risk  r presentted  by  com munication  difficulties  when  towinng  with  mo ore  than  on ne  person/operrator 

Rigid articulated attachm ment ‐ Proviides greater  control whe en towing, alllows heavy  machinery tto  derground ass it can be pu ushed and pu ulled  be easily positioned und

There is min nimal risk of a an accident bby an uncontrolled move ement of thee towed vehiicle 

Simplicity off use saves tiime and reduuces risk of incorrect cou upling, thus i mproving sa afety.   

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ENVIR RONMENTT AND COM MMUNITYY ‐ CHARB BON  Title  Seed Bank Project – An investme ent in the futture. 

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.    Community expectaations and Government aagency requ uirements for rehabilitatted land, posst mining, arre  constanttly  becomin ng  more  one erous,  expennsive  and  detailed.  Cha arbon,  and  tthe  mining  industry  as  a  whole, rrisks community condem mnation and rregulatory barriers such as approval  and lease re elinquishmen nt  delays iff it does not rehabilitate to a high staandard. 

Solutio on:  What, how the soluttion came ab bout, how thee solution mitigated the risk.  Industryy  best  practtice  rehabiliitation  usingg  innovative e  revegetatiion  and  moonitoring  techniques  arre  indicated. Charbon’ss Seed bank,, use of varioous soil ame eliorants, aerrial direct seeeding and co omprehensivve  have allowed d us to achievve best practtice.  monitorring regime h How thee solution go oes beyond ccompliance:   Simple aand less effeective rehabilitation tech niques and tthe resulting g ordinary reesults are stilll accepted b by  governm ment agenciees if they com mply with thee basics of a stable, susta ainable landsscape as the e end producct.  The Chaarbon metho od rehab allo ows complexx ecosystems  to be fabrricated and m monitored  in n a landscap pe  sculpted d to reflect natural proce esses and forrms. Not yet required Government –  but it won’t be long!  How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  (that is,  the solution n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  site operates).  The  elem ments  that  eventually  e re esult  in  the  rehabilitatio on  of  mined land  begin  synergising  years  earlieer,  with finaancial planning and man nagement, cllimatic observations and d open‐cut m mining logistics and timin ng  being crritical to even ntual successs. No one peerson can driive this outco ome, and thee rehab of la and must takke  o matter who o runs the en nvironmentaal part of the operation.  place no

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  en adop pted elsewhere? 

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Centenn nial benefits  by being ab ble to demonnstrate that  the compan ny is committted to susta ainable futurre  by  usingg  the  best  avvailable  science  to  replaace,  and  in  many  m cases  improve  i a  laandscape  aftter  a  valuable  resourcee has been o obtained – a w win‐win situ ation for the e company, tthe industry  and society as a whole. 

 

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ENVIR RONMENTT AND COM MMUNITYY – MAND DALONG SOUTH PRO OJECT  Title  Community engagem ment 

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.  

Engaging  op penly  and  honestly  withh  a  commun nity  that  will  be  potenttially  impactted  by  futurre  mining activvities 

Associated  risk:  Creatin ng  concern//angst  in  the  community  resulting   in  elevated d  communitty  a Centtennial  Coal   resulting  in n  delays  in  the  t project  and  restrictting  access  to  t opposition  against  undertake eexploration drilling and baaseline envirronmental in nvestigationss 

How this problem was iidentified: CCommon issu ue across Centennial’s o perations an nd the minin ng  industry  in  general  g and  similar  issuees  have  bee en  highlighte ed  by  recent t  projects  in  the  area  (i.ee.  Wallarah 2).. 

Solution n and how it  goes beyond compliancce:  What, how the soluttion came ab bout, how thee solution mitigated the risk.  

Understanding the comm munity (e.g. Us of ABS daata and revie ewing properrty titles) 

Engaging with the comm munity early  in the process 

Using  different  medium ms  to  commuunicate  with  the  commu unity  (meetinngs,  informa ation  session ns  open day etch) 

Educating th he communitty (e.g. Throuugh technicaal informatio on sessions) 

Being open, honest and trustworthyy 

Personalising  the  engaggement  (e.g..  Face  to  face  meetingss,  understan ding  individual  concerns,  taking time etc.) 

Gaining feed dback and co ontinuous im mprovement in engageme ent. 

Community  consulttation  is  req quired  at  alll  sites  and  for  all  proje ects  howeveer  the  level  and  type  of  o engagem ment  is  depeendent  on  the  t type  andd  scale  of  th he  project.  The  T communnity  engagement  processs  utilised  by  the  Man ndalong  Soutthern  Extenssion  project  team  utilise es  best  pracctice  measurres  to  engagge  with thee communityy and allow tthe communnity to provide input into the processs. Consultattion has beeen  regular  and  ongoingg  throughou ut  the  proje ct.  Engagem ment  strategies  have  adaapted  as  the  project  haas  n the projectt phase and ffeedback pro ovided by the communityy.  progresssed based on  

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How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  (that is,  the solution n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  site operates).  Community engagem ment undertaken by all tteam membe ers – not justt reliant on oone individua al.  Engagem ment  strateggy  develope ed  and  madde  publicallyy  available  –  – resulting  in  requirem ment  to  meeet  commitm ments madee.  Community engagem ment activitiies are discuussed at regu ular team meetings, wit h mine man nagement an nd  o re‐enforce importance  of engagement and ensu ure any com mitments arre kept.  general managers to Strategiees  implemeented  to  gain  feedbackk  from  com mmunity  to  ensure  conttinuous  imp provement  in  i commun nity engagem ment. 

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?  The com mmunity engagement und dertaken hass resulted in: 

 

Good comm munity relatio ons betweenn the commu unity and the e company w with a high le evel of trust iin  the company 

Allowing Centennial to ccontinue to  go back to landowners  to undertakee additional  activities no ot  drilling, installing monito ring bores ettc.)  previously reequired (i.e. Additional eexploration d

Reduced com mmunity con ncerns or tennsion within the community as everyyone knows what is goin ng  on, timefram mes etc. 

Establishing  Centennial  as  a  goodd  corporate  citizen  witthin  the  co mmunity  fo or  the  futurre  operations aas mining pro ogresses intoo the area.   

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ENVIR RONMENTT AND COM MMUNITYY – MAND DALONG SOUTH PRO OJECT  Title  Sound reeduction on surface drilling rigs 

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.  EL6317  covers an arrea of 45 squ uare kilomettres of rural  landscape. T The backgrouund day time noise leveels  are geneerally low (~~40 dBA). Op perating onee to two drill rigs in this  environmennt with potentially hostile  land holders adjacen nt to the Doo oralong Valleey was considered a high h risk to not bbeing able to o drill.  The drill rig operators are expose ed to sound  levels of aro ound 95 dBA at the operaating platform.  Solution n and how it  goes beyond compliancce:  What, how the soluttion came ab bout, how thee solution mitigated the risk.  Two deccisions were  made, firstlyy not to drilll with hamm mer and compressed air bbut with rota ary and wateer  circulation and secondly to insta all sound pro ofing materiial on the driill rig.  Noise reeadings weree taken prior to commen cement of th he exploratio on programm me and a serries of 500mm m  wide  an nd  2400mm  high  sound  panels  weree  purchased d  and  installed  along  th e  two  sides of  the  rig.  A  sound reeducing blan nket was insttalled in areaas where the panels could not be insttalled.  The panels reduced the sound le evels at the ooperator by 1 1.5dBA and a at 200m by 88 dBA.  Although the rig cou uld operate w within the D ECC interim noise guidelines at 200m m, the reducction of 8 dB BA  has  mad de  a  big  diffference.    Ass  such  it  hass  allowed  drrilling  to  takke  place  witthin  160m  of  a  residencce  without complaint.  The  pan nels  have  lassted  the  2  years  and  ouur  second  drrill  rig  has  be een  fitted  ouut  with  the  same  panels.  Howeveer, more sturdy brackets haven manuufactured forr this installation. 

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?  The pan nels have dem monstrated  to the comm munity the ccompany’s w willingness too acknowledgge the impacct  of noisee and go beyyond  complyying with thee DECC noise e guidelines. They  have  allowed us  to operate iin  close pro oximity to ou ur neighbours.  They  are  easily  transferable  to o  other  Centtennial  sitess  and  can  be  b readily  m manufactured d  to  differen nt  dimensions.   

 

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ENVIR RONMENTT AND COM MMUNITYY – NEWST TAN  Title  Newstan n Clean Wateer Diversion Drain (CWD D) 

Identiffied Probllem  What, w who identified d the problem m, how the pproblem wass assessed, w what was thee identified risk associateed  with thee problem.  Limited  water storage capacity  within the SSouthern Rejject Emplace ement Area  (SREA) and  a high risk o of  dirty waater discharges as a result of surface w water flows into the SREA catchmentt. 

Solutio on  What, how the soluttion came ab bout, how thee solution mitigated the risk.  Newstan practice  in  separating  the  n  has  attempted  to  imp plement  induustry  best  management  m t clean  an nd  dirty waater streams into two discrete draina ge systems w within the SR REA.  How thee solution is integrated into the busiiness?   That is,  demonstrated continuitty of the sol ution at the site ‐ over  a number off years) and independen nt  (that is,  the solution n is beyond jjust one perrson driving  the outcome ‐ it is trulyy integrated  into how th he  site operates).  The com mpleted CWD DD will be approximatel y 1600m lon ng with a catchment areea exceedingg 120 Ha. Th he  CWDD  which  was  designed  by  senior  pproject  enggineers  will  have  a  deesign  capacity  to  divert  approxim mately  40,000  m3  of  clean  water  around  the e  SREA  during  a  storm  event  with h  an  Averagge  Recurrence Interval (ARI) of 20 yyears and a sstorm duratio on period of 3 hours.  Since the CWDD hass been constrructed theree have been n no discharge e events from m the SREA. 

Benefiit  Benefit o of the solutio on to Centen nnial ‐ how ccould other ssites (or indu ustry) benefiit from the so olution, has  it  been ad dopted elsewhere?  Centenn nial  operatio ons  should  consider  oppportunities  to o  install  clea an  water  divversion  wherre  possible  to  t maximisse the capaciity available within dirty  water manaagement stru uctures and tto reduce th he risk of dirtty  water diischarge eveents.     

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HEALTH AND SAFETY – AIRLY  Title  Centennial Airly Coal QDS Hydraulic Dissipation Device  Identified Problem:  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    Grahame  Collins  identified  potential  personnel  hydraulic  fluid  hazard  and  quick  coupling  component damage with conventional QDS quick coupling systems  This  is  due  to  the  ability  to  have  stored  hydraulic  pressure  trapped  in  the  QDS  and  operating  machine circuit due to the hydraulic circuit being restricted. 

Solution  What, how the solution came about, how the solution mitigated the risk.  The  solution  was  to  insist  via  Airly  purchasing  standards  that  OEMs  include  in  their  design  pressure dissipation devices on the supply of QDS attachments.  How the solution goes beyond compliance:  This coupled with site specific DMS CT10 LHDs Airly have dissipation device on both sides of the  QDS quick connect attachments.  This standard of operator protection is not an industry standard.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  By Airly insisting compliance by OEMs to Airly purchasing standards, OEM’s have been forced to  develop system of dissipation for each type attachment they have supplied. Some OEMs have  taken these design changes and made them standard features for their products.   This has in effect raised the standards for supply of QDS equipment across our industry. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere? 

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This system provides a greater level of safety for all operators and lessens equipment damage  when it comes to connecting and disconnecting QDS attachments.  This system has been identified as best practice during recent Centennial audits and lessons the  likelihood of reportable incidences to the mining inspectorate. 

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HEALTH AND SAFETY – ANGUS PLACE  Title  Baldwin & Francis Variable Speed Drive (VSD) unit Positioning plate    Identified Problem:  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    B&F VSD drive unit weighs about 60kg and has to be lined up within two slides, whilst holding  the weight of the drive. This process can be very awkward and puts a lot of strain on the lower  back as the positioning of the drive makes it hard to use proper lifting techniques. Cables must  also be connected to the drive at this stage making the process even more difficult. 

Solution  What, how the solution came about, how the solution mitigated the risk.  The platform eliminates the need to line up the drive whilst holding the weight, and allows you  to use proper lifting techniques to lift it onto the plate. It is then just a matter of sliding the drive  into place and connecting the cables.  How the solution goes beyond compliance:  Using  this  platform  makes  the  process  of  changing/fault  finding  the  drives  a  lot  safer  for  the  men  working  on  it  and  a  lot  easier  and  quicker,  thus  minimising  injury  and  downtime  at  the  worksite.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  With a total of 9 B&F drives at the colliery this unit has the potential to be integrated into the  business by making it a standard piece of equipment. Multiple units can be produced and placed  at each belt starter. Standard Work Procedures (SWP’s) can be produced outlining the process  including the correct use of the plate.  The use of this unit is in the best interest of every worker, as the solution has come about from  the thoughts of anyone who has attempted this task. 

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Beneefit  of  the  ssolution  to  C Centennial  ‐ how  could  other  sites  (or  industry))  benefit  fro om  the  soluttion, has it beeen adopted d elsewhere? The  positioning p plate greatlyy improves th he process o of changing tthe B&F drives by reducing risk  njury  to  wo orkers,  which h  has  alwayys  been  a  ggoal  of  Centtennial  as  well  w as  miniimising  of  in dow wntime.  I  beelieve  this  u unit  can  be  of  great  benefit  for  other  o sites  utilising  thee  same  equipment. 

 

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HEALTH AND SAFETY – CLARENCE  Title  Harness for crossing the Lithgow No.2 Dam wall. 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    

Risk assessment team in RA‐2152 

Risk  of  injury  from  accessing  Lithgow  No.2  dam,  survey  pin  and  seepage  monitoring  installation and ongoing access 

Inability to install Australian Standard compliant guard/railing. The dam wall is greater  than 100 years old and was not designed with access to the top of the dam wall in mind 

The  installed  infrastructure  had  to  be  appropriate  for  the  task  without  encouraging  misuse by the public in a publicly accessible place. 

Solution  What, how the solution came about, how the solution mitigated the risk.  Unable to eliminate/substitute the risk so the risk assessment team reviewed ways of mitigating  the consequences of injury to personnel that would result from a fall from the dam wall.  How the solution goes beyond compliance:  

The problem and solution were identified in a risk assessment initiated and conducted  by Clarence Colliery 

The risk assessment team reviewed the need for the installation of anchor points on the  wall that met the requirements of AS 1657‐1992. 

How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  

Risk assessment conducted by risk assessment team 

Process involved identifying who required access to the Lithgow No.2 dam 

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Personneel who have received training in accessing the dam m wall 

System o of monitoringg is limited to o personnel who have reeceived trainiing in accessing the  dam wall. 

Ben nefit  Beneefit  of  the  ssolution  to  C Centennial  ‐ how  could  other  sites  (or  industry))  benefit  fro om  the  soluttion, has it beeen adopted d elsewhere? 

A  metho od  to  mitigatte  the  conseequence  of  a  fall  by  personnel  requ uired  to  und dertake  monitoriing tasks acro oss and arou und the dam wall 

Able to b be adapted aas an additional control ffor the otherr tasks wheree the risk of aa fall is  identified d and wheree the installaation of compliant guarding/railing iss not availab ble as a  control. 

 

 

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HEALTH AND SAFETY – MANDALONG  Title  Reliable Sealed Area Monitoring at Mandalong  

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    Waste areas are sealed off and inertised with methane to achieve a fuel rich inert state. This is  done  to  ensure  an  inert  atmosphere  that  is  not  flammable/explosive  and  will  not  support  spontaneous combustion.  Major  disasters  such  as  Sago  have  highlighted  the  criticality  of  sealed  area  management,  and  this  in  turn  has  driven  increased  focus  and  regulation  with  respect  to  the  requirement  to  withdraw people where explosive atmospheres are detected  Unfortunately  no  seal  is  100%  airtight,  and  changes  in  pressure  due  to  barometric  pressure  variations or ventilation changes can cause  seals to “breathe” which in  turn can  cause diluted  samples in the fringe area around the seals where sampling is typically taken from. This dilution  can  cause  false  indications  of  an  explosive  atmosphere,  which  could  trigger  evacuation  un‐ necessarily.  Also,  any  dilution  will  reduce  the  concentration  of  products  of  combustion  which  may lead to spontaneous combustion event not being detected.  Alternatively,  repeated  “false  alarms”  triggered  by  dilution  could  normalise  people  to  the  occurrence and contribute to a real risk not being identified. 

Solution  What, how the solution came about, how the solution mitigated the risk.  The solution has been to utilise gas drainage boreholes, which are typically fully grouted, to act  as a conduit for sampling in a location remote from seal sites.  This solution was conceptualised, developed and implemented by the Technical Services Team  at Mandalong Mine.  It mitigates the risk by sampling from a point in the sealed area remote from sources of leakage  and thus gives a true reading of the sealed area atmosphere.  How the solution goes beyond compliance: 

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The  amount  of  monitoring  points  is  not  specified  by  legislation.  Mandalong  has  attempted  to  maximise  knowledge  of  sealed  areas  to  best  control  the  risks  by  maintaining  a  significant  number of sample points.  A “compliant” solution would be to have a minimum number of sample points, thus minimising  the risk of an erroneous sample triggering evacuation.  Mandalong  has  elected  to  maximise  sampling  to  gain  maximum  knowledge  regarding  the  composition of gases in the sealed area, thus going “beyond compliance”.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  This solution has been developed totally on site. It utilises the pre drainage boreholes which are  always drilled as part of the mining process.  This sampling system will be documented as a standard to ensure consistent application.  Costs are not significant but are integrated into Mandalong’s Business Plan.   The  finalisation  of  the  implementation  of  this  innovation  will  be  included  in  the  SPDR  for  the  Ventilation Officer and Technical Services Superintendent in 2012. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  This innovation is of major value to Mandalong and any other mine that manages sealed areas.  It  does  require  the  availability  of  in  seam  boreholes,  but  many  “gassy”  mines  conduct  pre‐ drainage and have these boreholes available.  Accurate  monitoring  of  sealed  areas  is  critical  to  managing  the  major  mining  risk  of  an  underground explosion or heating – this innovation addresses the major issue of sample dilution  that impacts all similar operations.   

 

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HEALTH AND SAFETY – MANDALONG  Title  U/G Bin Top Dust Suppression  

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    This problem has been identified from inspections and reports that have escalated to the OHS  Committee.  The problem has been created by the installation of a bin top sizer in an environment of limited  airflow on the intake side of all operations at the mine.  This has created a OHS issue due to high airborne dust exposure levels that Mandalong has been  trying to solve for a number of years. 

Solution  What, how the solution came about, how the solution mitigated the risk.  A  solution  has  been  developed  by  engaging  experts  in  this  area  from  the  University  of  Wollongong  (UOW),  who  are  in  turn  working  with  a  company  called  Techpro  on  the  development of ultrasonic dust suppression sprays.   The  expertise  of  these  organisations  has  been  used  to  develop  an  improved  dust  suppression  system  for  the  bin  top  area,  utilising  the  UOW  skills  in  airflow/dust  modelling  and  the  suppression ability of these newly developed sprays.  How the solution goes beyond compliance:  This solution has produced reduction of 30% in the amount of dust generated in this area.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  Inquiries were initially made into this technology by the Development Superintendent looking to  improve the dust scrubbing ability of the “Drop Box” on the development monorail. 

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Due to the issues with the bin top area, it was decided this was a good area to conduct a trial.  Development  and  Services  Teams  worked  together  on  this  trail,  and  the  process  has  been  overseen by the OHS Committee who wants to find a solution to this problem.   

 

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Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  This solution has produced a measured reduction of 30% in the airborne dust generated in this  area.  The technology used has application in other areas at Mandalong and at all underground coal  mines.   

 

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HEALTH AND SAFETY – MANDALONG  Title  Automated Diesel Exhaust Test Station  

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    The testing  of the quality  of diesel exhaust  gases  in the diluted state  underground is a critical  part of providing a safe and healthy workplace.  Unfortunately,  there  are  a  number  of  variables  that  impact  on  the  test  result  which  include  airflow,  positioning  of  detector,  operation  of  machine  during  testing  and  operator  reading  instrument. 

Solution  What, how the solution came about, how the solution mitigated the risk.  The solution has been to install an automated system which controls the variables above. The  test station controls airflow, controls monitoring variables and send the test results to control by  email.  As with all aspects of the mining operation this automation controls the impact of the variables  controlled by operators and ensures accurate testing of diluted exhaust gases.  An essential part of this project has been the preparation of a training video, and this has been  done on site with no external resources.  How the solution goes beyond compliance:  This  system  goes  beyond  compliance  by  also  automating  the  recording  process  by  emailing  results to control.  The  video,  prepared  for  employee  training  also  goes  beyond  minimum  requirements  and  has  improved the effectiveness of implementation.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates). 

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This  solution  was  planned  and  developed  by  Mandalong,  utilising  commercially  available  equipment.  It  was  included  in  the  2011  Business  Plan  and  has  recently  (Dec  2011)  been  completed. The testing station is now being implemented by training each of the mining crews,  which is based on a training video fully developed on site.   

 

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Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  Similar  testing  stations  have  been  installed  at  other  mines,  and  this  type  of  facility  will  be  a  necessity for all larger operations.  It could be of benefit to all underground mines.   

 

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HEALTH AND SAFETY – MANNERING  Title  Improved performance of on board dust suppression system. 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    Mannering purchased a new Joy 12CM12 continuous miner complete with on‐board ventilation  system. This machine was considered to be a dusty machine and the workforce identified that  the airborne dust created from operating this machine were far in excess of existing equipment. 

Solution  What, how the solution came about, how the solution mitigated the risk.  Dust  is  now  mitigated  using  two  main  controls  being  ventilation  and  dust  suppression.  It  has  been suggested that a new set of spray manifolds be installed at the bottom of the cutter head.  These new spray manifolds will direct atmoised water both forward at the cutter picks and also  downwards.  The  sprays  directed  forward  will  have  a  hollow  cone  spray  pattern.  This  spray  formation will suppress dust at the point it is liberated. The sprays directed downward will have  a  flat  spray  pattern  with  the  spray  being  directed  perpendicular  to  the  centreline  of  the  machine.  The  sprays  directed  downwards  will  form  a  curtain  of  water  to  hold  the  dust  at  the  face  giving  it  longer  to  drop  from  suspension.  This  could  reduce  dust  escaping  between  the  underside  of  the  cutter  frame  billowing  back  alongside  the  mainframe  and  entering  the  operators work environment.    

 

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HEALTH AND SAFETY – NEWSTAN  Title  Integrated First Response Station 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.    After  reviewing  a  number  of  underground  simulated  emergency  response  exercises  it  was  identified  that  the  first  aid,  emergency  and  CABA  equipment  was  being  stored  in  different  containers and in some cases in different locations. This could result in confusion in the event of  an incident underground.  Newstan currently utilises M.P.V attachment CABA pods with the emergency gear stored in the  base of the pod, however if these pods are placed too close to other objects, or in muddy floor  conditions, then it may become difficult to retrieve the emergency gear from the pod. This was  highlighted  by  a  Department  Mines  Inspector  who  indicated  that  this  had  been  a  problem  at  other mines. 

Solution  What, how the solution came about, how the solution mitigated the risk.  To centralise and contain all first aid, emergency and CABA equipment in the one area Newstan  designed an Integrated First Response Station (CABA, First Aid and Emergency Pod), that can be  transported  either  by  QDS(quick  detach  system)  attachment  directly  onto  a  LHD  (load  haul  dump) machine or with forks, and had two built by Dräger Australia.  How the solution goes beyond compliance:  After appraising the first response equipment used at other mines and with an understanding of  the  requirements  of  emergency  response  Newstan  has  designed  and  had  manufactured  an  Integrated  First  Response  Station  which  retains  this  vital  equipment  in  an  easily  accessible,  single location.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates). 

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By centralising all emergency equipment in the one pod, Newstan has simplified the process of  transporting this equipment when relocation is required, utilising the current LHD QDS system  and eliminated any confusion that may have occurred when locating this resource in the event  of  an  emergency.  Discussed  with  the  HSEC  committee  and  Newstan’s  current  workforce  the  pods appear to have had only positive feedback prior to their introduction underground  After appraising the first response equipment used at other mines and with an understanding of  the  requirements  of  emergency  response  Newstan  has  designed  and  had  manufactured  an  Integrated  First  Response  Station  which  retains  this  vital  equipment  in  an  easily  accessible,  single location. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  As  a  central  location  for  all  emergency  equipment  contained  in  a  production  unit,  these  pods  could simplify the transportation and implementation of emergency equipment in the event of  an underground incident at any underground mine site. 

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HEALTH AND SAFETY – SPRINGVALE  Title  The use of Dincel PVC formwork for sump walls and hand rails 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  When concrete lining Drive Head sumps the normal practice at Springvale was to use form ply  and bolt the ply to the sides or ribs of the sump, pour the concrete, remove the forming after  concrete set then manufacture and install a hand rails. 

Solution  What, how the solution came about, how the solution mitigated the risk.   Springvale conducted a Risk Assessment then trialled the  product call Dincel.  Light weight, Pre‐cut on surface, Fire resistant, Can be extended to include hand railing.  How the solution goes beyond compliance:  There was always a delay between the completion of the sump walls and the installation of the  pipe style hand railing. The sump had to be fenced off until the hand railing was completed. In  this process the hand rail is part of the sump wall and is installed at the same time.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  This process will be utilised at all future sumps. There is a SWP developed for the process. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  Most LW mines have Drive Head sumps to manage the fines and to allow ease in hosing the jib  area down. This product and process could be used at all Centennial Mines that have sumps.   

 

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HEALTH AND SAFETY – SPRINGVALE  Title  Serious Incident Presentations (SIPs) 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  A serious incident occurred at Springvale on 7 September 2011 where a Deputy attempting to  dewater a waterhole slipped and fell onto a moving conveyor and became jammed under the  structure‐mounted auxiliary fan.  Although his injuries were minor there was potential for a more serious consequence.  An investigation was conducted and found there was a deviant/cultural violation.  The violation of not isolating correctly when working on or around conveyors could be present  throughout the mine. 

Solution  What, how the solution came about, how the solution mitigated the risk.   This  incident  was  classified  under  the  Springvale  Disciplinary  Procedure  Policy  as  a  “Major  Breach” resulting in suspension without pay or dismissal.  However, would suspension without pay or dismissal change the employees’ attitudes towards  unsafe practices when working around conveyor belts?  It  was  decided  with  the  approval  of  the  Government  Inspector  and  the  investigation  team  to  arrange a series of presentations conducted by the Deputy to all crews showing graphic photos  of the re‐enactment.  How the solution goes beyond compliance:  Would disciplinary action followed by a standard tool box talk be sufficient? Probably not. This  process added the personal touch and brought real emotion to the presentations, in particular,  when the Deputy  showed photos of his  kids and  spoke about his thoughts when  faced with a  near death situation.  At all sessions you could hear a pin drop during the presentation  How the solution is integrated into the business?  

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That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  This is not the solution for all serious incidents. If this situation or something similar occurred at  Springvale again then disciplinary action would have to be followed.  This  has  proven  to  be  a  very  powerful  communication  tool  but  only  effective  if  the  person  delivering  the  presentation  is  firstly  committed  and  believes  in  the  process  and  is  of  such  character that people respect what they are saying.  This communication tool/process could be utilised throughout Centennial mine sites. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  The emotional and visual aspect of this tool gets the message home.   If this tool/process is used correctly then one incident at one site can influence or change the  attitude to safety and environment at all Centennial sites.   

 

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ENVIRONMENT AND COMMUNITY – ANGUS PLACE  Title  School Engagement Program 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.   Angus  Place Colliery  identified  an  opportunity  to  assist  local  school  children  with  their  studies  after a year 6 students approached a member of staff to help with an assignment on fossil fuels  and renewable fuels during 2010. As the assignment given was linked primary school curriculum,  it was believed that Centennial could provide factual information on the relevant subject in the  syllabus which could benefit the community.  Solution:  What, how the solution came about, how the solution mitigated the risk.   Angus  Place Colliery  approached  principals  of  local  schools  who coordinated a  meeting  where  Angus  Place  expressed  their  interest  in  working  with  the  students  and  teachers  to  provide  information  regarding  fuel  sources,  energy,  mining  techniques  and  their  associated  environmental impacts.  The teachers were excited at the opportunity to work with the colliery  and to discuss how centennial proposed to deliver the information to the students.  Angus Place provided proposed the following program to the teachers which was accepted and  in turn delivered by colliery staff:  

School  visit‐  Site  Environmental  and  Community  Officers  to  attend  and  deliver  a  presentation  linked  to  the  syllabus.  Key  Topics  discussed  included:  What  is  energy,  Different Forms of Energy, Examples of renewable an non‐renewable forms of energy,  How coal is mined, Who Centennial is and what we do, why is coal a valuable resource,  how  is  coal  converted  to  electricity,  advantages  and  disadvantages  of  coal  based  electricity,  how  they  could  reduce  their  impact  on  the  environment  and  how  to  save  energy at home.  

Teachers  were  provided  a  Handbook  which  provided  more  detailed  information  and  activities  students  could  complete  in  the  classroom  or  for  homework  such  as  quizzes,  energy source sudoku, word searches and cross words 

Angus Place provided funds to transfer students to and from the Mines Rescue Station 

At the Mines Rescue Station students were : 

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‐Given a brief presentation on mining and the environment to recap what was learnt  during the school visit 

‐Shown an energy, mining and spill response video 

‐Shown mine rescue vehicles and emergency equipment e.g. CABAs 

‐The  students  were  then  spilt  into  3  groups  which  rotated  through  virtual  reality  software  showing  underground  mining,  3D  Dome  showing  open  cut  mining,  identified  how  different  substances  can  be  distinguished  and  tested  at  home  (e.g.  litmus  paper  and  pH  probe),  demonstrated  how  spill  kits  can  be  used  to  prevent  harm to the environment and what can be used to home to stop and clean up spills. 

How the solution goes beyond compliance:  The school engagement program for Angus Place was not focused on mining activities occurring  on  site  but  rather  providing  factual  information  and  practical  assistance  to  primary  school  students and their teachers. It was not required to be completed under our project approval nor  had it had it been requested to be completed by the local community.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  After  the  opportunity  to  participate  in  a  school  engagement  program  was  identified  it  was  embraced as a proactive step to integrate Angus Place into the Community. The presentations  and activities to be completed were reviewed by members of staff with children prior to delivery  who similarly saw the program as an excellent way to enhance student learning.  Many  Different  members  of  staff  participated  over  the  week  including  Environment  and  Community Officers, Mine Manager, Compliance Manager and the Mines Rescue Station.  It was also well received by the HSEC Committee and many members of staff congratulated the  team  on  their  efforts  and  commented  on  how  well  received  the  program  was  by  their  daughter/son. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  For the Lithgow region centennial is a large source of employment. Many children have a limited  understanding  of  what  their  parents  do,  where  they  work  and  under  what  conditions.  The  program exposed the children in a safe and controlled environment to the working life of their 

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parent,  brother  or  sister,  grandparent,  aunty  or  uncle  or  neighbour.  The  program  eased  concerns raised by students about the safety of the mining environment.  In summary Angus Place promoted a positive image of how and why mining is important for the  local community and how we manage our environmental impacts.   As  all  Centennial  operations  form  part  of  the  local  community  it  is  an  opportunity  for  other  mines to pursue which would enhance their image within their own community.  

 

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ENVIRONMENT AND COMMUNITY – ANGUS PLACE  Title  Water Management System Improvements undertaken at Angus Place Colliery  

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  Historically Angus Place has been non‐complaint with the water quality criteria prescribed in the  colliery’s  EPL.  After  reviewing  the  water  management  system  it  was  evident  that  to  achieve  compliance with the water quality criteria consistently significant action would be required to be  undertaken. 

Solution  What, how the solution came about, how the solution mitigated the risk.   The colliery has designed and implemented several innovative water management strategies at  various discharge points across the site. These include:  

Construction of both a polyethylene and galvanized steel pipeline between the point on  the  surface  where  water  exits  the  underground  and  discharges  via  LDP001.  It  is  the  intention of splitting a portion of the water through the pipeline and wetland system to  mix the pH of the underground water to below 8.5 consistently. Bench scale testing has  demonstrated that by preventing the water coming in contact with air the pH remained  similar to the pH of the water underground which was measured at 7.86. This pipeline  was commissioned in November 2011 and results obtained to date have been below the  90th percentile limit of 8.5. The system is scheduled to be further upgraded in the 1st  quarter of 2012 with a pH probe linked to an acid dosing system and a turbidity probe  liked  to  a  coagulant  dosing  system  to  aid  in  the  management  of  pH  and  TSS  under  altered pumping conditions 

Implementation of controlled discharge system at LDP002 whereby additional sampling  sites have been established to determine the water quality at the 2 settling areas prior  to  discharge.  A  pipeline  with  a  knife  valve  has  been  established  between  the  2  ponds  and the discharge point. It enables treatment strategies such as coagulant or acid dosing  to occur if water is outside the water quality criteria specified in the EPL. Water level at  the  ponds  can  also  be  managed  at  a  lower  level  to  enable  the  capture  of  rainfall  and  allow the residence time to be increased. 

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Engaged a consultant who has successfully designed a site specific coagulant to reduce  the suspended solids (coal fines and clay collides) contained within the runoff from both  the ROM stockpile and Kerosene Vale stockpile area. This is used to treat water settling  in the pond prior to discharge and in an automated dosing system upstream of LDP003  to  treat  incoming  water.  This  system  is  currently  being  upgraded  to  adjust  the  dosing  rate of coagulant to suit the volume of water entering the point. 

  Additionally  the  colliery  has  undertaken  the  following  to  demonstrate  improvements  in  water  quality management:  

Developed  a  TARP  which  outlines  the  action  to  be  taken  as  water  quality  limits  are  approached or exceeded. 

Is using weather forecasts to predict high risk rainfall periods and has analysed historic  metrological  data  to  determine  trends.  This  enables  the  site  to  adjust  the  water  management  infrastructure  to  prepare  for  additional  sediment  which  is  contained  within runoff during rainfall events. 

Approached OEH remove Environmental Protection Licence condition L4.2 which stated  “the  licensee  must  not  discharge  from  point  3  unless  discharge  from  point  3  occurs  solely as a result of rainfall event at the premise that is greater than or equal to a 1 in 5  year occurrence interval of 24 hours duration”. This was accepted by OEH on the 22nd  of  August.  This  alteration  has  allowed  the  colliery  to  capture,  treat  and  then  release  water to maximise the free board in the settling area 

Concreted and lined between settling ponds and discharge points to prevent additional  solids being collected between the ponds and weir and thereby preventing changes in  water quality following treatment to a known TSS concentration 

Established a sediment removal schedule for settling ponds to enhance holding capacity  and therefore increase residence time to allow suspended solids contained within runoff  to be removed 

Installed V drain near coal stockpile to pile water into a large settling pond 

Lined  the  entry  points  of  settlings  ponds  with  ballast  and  installed  gabion  baskets  to  prevent additional solids post flocculation being collected and to filter incoming water. 

How the solution goes beyond compliance:  The  colliery  is  committed  to  continually  improving  the  water  management  system  to  prevent  non‐compliances.  The  improvements  works  undertaken  and  the  action  taken  to  prevent  non‐ compliances during high risk periods is a reflection of the dedication of the site to control water 

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quality. The work undertaken demonstrates the journey the site has taken throughout 2011 and  is reflected in the sites performance.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  The entire site has a heightened awareness of how environmental performance is linked to our  licence to operate.  Members of the HSEC team were taken to the licensed discharge points and  suggested  improvement  works.  Staff  accompany  the  environmental  team  during  inspections  have questioned water management infrastructure and comment on the levels and clarity of the  water  on  site  and  question  what  we  are  doing  to  fix  it.  Environmental  awareness  slides  and  improvement works are also shown to the workforce regularly. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  It  is  critical  that  the  innovative  solutions  adopted  by  a  site  and  the  improvement  works  undertaken is communicated across Centennials operations so similar mines can adapt suitable  solutions to problems shared.  By  promoting  the  importance  of  environmental  performance  amongst  the  entire  staff  the  success  of  improvements  works  has  been  celebrated  and  aided  in  the  integration  of  environment into the business.   

 

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ENVIRONMENT AND COMMUNITY – CLARENCE  Title  CHPP Diesel Tank Isolation System 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  A  Hydrocarbon  spill  during  the  refuelling  of  equipment  needed  to  be  contained  within  the  refuelling  bund.    The  project  team  identified  the  concept  and  criteria  that  guided  the  consultants when designing the refuelling system. The system was developed from a desire to  ensure contamination of an area was kept to a small footprint and the process was automated. 

Solution  What, how the solution came about, how the solution mitigated the risk.   Through  the  design  process  an  automated  isolation  system  was  developed  to  contain  a  hydrocarbon spill at the CHPP diesel tank refuelling bund.  How the solution goes beyond compliance:  The  idea  was  generated  by  the  project  team  during  a  review  of  the  proposed  design  for  refuelling at the CHPP diesel tank. The isolation system provided an additional barrier to contain  a hydrocarbon spill.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  The isolation system was included with the construction of the new above ground diesel at the  CHPP in 2011. The isolation system is also proposed for the new above ground diesel tanks to be  constructed at the Pit Top. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  The isolation system could be applied to other bunded refuelling sites on other mines. 

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ENVIRONMENT AND COMMUNITY – MANDALONG  Title  Improved Dirty Water Management at Cooranbong Services Site  

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  Cooranbong  Services  site  has  been  the  cause  of  a  number  of  Total  Suspended  Solids  (TSS)  exceedances,  which  have  ultimately  resulted  in  Mandalong  Mine  receiving  a  Penalty  Infringement Notice from the EPA.  It was determined that positive action must be taken to reduce the risk of further recurrences.  Based  on  a  review  of  expert  reports,  it  was  identified  that  the  traditional  approach  of  using  settling dams to manage poor quality run off from Coal Storage Areas was not practical due to  the size of dams required and the surface area required for the construction of such dams. 

Solution  What, how the solution came about, how the solution mitigated the risk.   A  design  is  being  developed  to  install  a  series  of  vertical  surface  to  seam  boreholes  to  drain  sediment laden water from the existing water treatment dams into underground workings. This  water  will  then  migrate  towards  an  old  waste  workings  area  that  is  currently  used  for  the  treatment and storage of underground mine water. Due to the extensive standage area and the  significant  opportunity  for  solids  to  settle  out,  this  area  has  been  very  effective  at  producing  mine water with very low TSS levels.  A  critical  feature  of  this  innovations  as  its  design  is  the  fact  that  no  pumps  are  required  –  all  movement of water will be by gravity, which removes the risk of a plant failure, does not require  energy  thus  making  it  the  most  reliable  and  sustainable  solution.  It  does  not  rely  on  people  taking  action  –  when  the  water  rises  to  the  level,  discharge  into  the  UG  workings  will  commence.  How the solution goes beyond compliance:  Current licence limits are 50mg/l.  Based on Mandalong’s experience with the treatment of mine  water,  it  is  expected  that  water  discharged  from  the  mine  will  be  approximately  10‐20  mg/l  consistently. 

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This level is well below the licence limit and will significantly reduce the sediment loading on the  receiving waters.  How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  This innovation is an example of the integration of a number of disciplines within the mine to  achieve  an  environmental  improvement  objective.  Mining,  Engineering,  Surveying  and  Environmental people have all contributed to the design of this system.   The expenditure is integrated into Mandalong’s 2012 Business Plan.  As a capital project its progress will be monitored by normal management meetings.  The successful completion of this project will be integrated into the SPDR documents of Mining,  Surveying and Environmental people at the mine. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  This solution could be applied to other mines that have underground workings in proximity to  surface water treatment facilities, but would also require suitable storage area underground and  a suitable pumping system pump out the treated water.  Other mines utilise old workings for water management and tailing disposal, but rely on pumps  as part of the process.   

 

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ENVIRONMENT AND COMMUNITY – MANDALONG  Title  Power Factor Correction Control Upgrade 

Identified Problem  What, who identified the problem, how the problem was assessed, what was the identified risk  associated with the problem.  In 2000, Myuna installed two Power Factor Correction Plants. The original ABB controllers which  came  with  these  plants  had  no  alarms,  hardware  monitoring,  power  usage  metering  or  Citect  support. If a fault occurred on the plant, then the only notification was through an amber light  that  flashed on top of the Power Factor  Correction  Plants. In  2010, this light globe  failed. The  Units also tripped off, going unnoticed for 7 months.  Each  day  the  power  factor  correction  units  are not  working,  the  colliery  needlessly  consumed  29,551 kwh, which is equivalent to 26 CO2‐eT and costs the company $2,088.  For the 7 months the plants were offline, the Colliery consumed an additional 6,205,710 kWh,  5,523 CO2‐eT, and cost the Colliery more than $479,862.73. 

Solution  What, how the solution came about, how the solution mitigated the risk.   As a result, Myuna replaced the existing hardware with more robust technology. This involved  the installation of PLC controllers, Panel View touch screen interfaces and metering equipment  which can be integrated into the site SCADA system (Citect).   By upgrading the control system, reliable communication and monitoring have been established  enabling the user to be notified of a fault through the Citect alarm system.   This  new  system  not  only  allows  increased  monitoring  of  power  usage,  but  allows  Myuna  to  continue  to  save  electricity  and  reduce  carbon  emissions  by  decreasing  the  down  time  of  the  units.  How the solution goes beyond compliance:  The power factor correction units are not a legislative requirement.   The upgrade was also not a requirement, however it improves our monitoring abilities, and has  an  alarm  function  which  allows  Myuna  to  monitor  and  maintain  the  equipment  to  its  full  capabilities.  

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Each  day  the  power  factor  correction  units  are  working,  the  colliery  reduces  its  power  consumption 29,551 kwh, which is equivalent to 26 CO2‐eT.      How the solution is integrated into the business?   That  is,  demonstrated  continuity  of  the  solution  at  the  site  ‐  over  a  number  of  years)  and  independent  (that  is,  the  solution  is  beyond  just  one  person  driving  the  outcome  ‐  it  is  truly  integrated into how the site operates).  The  new  control  unit  is  linked  to  Citect,  and  doesn’t  require  a  person  to  check  the  units  manually.   If there is a fault or failure with the power factor correction units, Citect alarms informing mine  personnel of the problem.   The  controller  logs  the power  consumption  of  the  mine every  day  providing  a  wide  variety  of  information accessible to the user through Citect, these include:  

Approximate energy cost 

Power factor tariff charge 

Energy consumption across the peak, shoulder and off‐peak periods 

Average daily consumption 

Average power factor 

This  will  prevent  a  repeat  of  the  system  being  down  without  mine  personnel  being  aware.  Having the Power Factor Correction units working efficiently almost halves the required current  to achieve the same power output. This increases transmission and motor efficiencies, which in  turn results in extended motor life and smaller cable sizes. 

Benefit  Benefit  of  the  solution  to  Centennial  ‐  how  could  other  sites  (or  industry)  benefit  from  the  solution, has it been adopted elsewhere?  The installation of the new controller will mean that not only can we monitor our usage, there is  an automatic alarm through the Citect system if there is a fault. The new system also has fault  finding capabilities. This will allow the units to be repaired quickly and allows us to maintain the  system to its full potential. 

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Due to the Power Factor Correction Myuna’s energy consumption is reduced by approximately  32% through the improvement of transmission and motor efficiencies.   This  controller  can  be  installed  on  other  Power  Factor  Correction  Plants,  preventing  another  occurrence similar to what has occurred at Myuna Colliery.    

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HSEC Conference