Safe to Work January 2023

ISSUE 23 - JAN-FEB 2023

Maintenance is the key Ensuring safety and increasing efficiency 2023 | JAN-FEB | ISSUE 23

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THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY

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Hazard avoidance

Connectivity

Safety training

Health and wellbeing

Expect more sustainability

Solving the challenge of scrap tyres in a way that’s practical and sustainable could be around the corner for Australia. After successfully opening a thermal conversion OTR tyre recycling facility in Chile that converts scrap tyres into base elements for reuse, Kal Tire is ready to bring this scalable solution to other regions.

Kaltiremining.com

Comment Maintenance is the key to safety

A MINE SITE WITH WELL-MAINTAINED EQUIPMENT CAN IMPROVE SAFETY OUTCOMES WHILE LIMITING UNEXPECTED DOWNTIME.

PAUL HAYES

T

rucks, drills, excavators, loaders, diggers, conveyor belts, hoists and pulleys, the list of machinery and equipment on a mining operation is just about endless.

Of course, it’s vital all of that gear is kept in tip-top shape, not only for the optimum operation of the mine itself but also for the safety of the people on and around it.

Proper maintenance of mining equipment increases efficiency and performance and, in turn, improves safety.

Failing to undertake necessary maintenance can result in faulty equipment, potentially putting employees in danger.

That’s why this issue of Safe to Work examines some of the approaches to maintenance that are contributing to a safer mining industry.

One of the biggest keys to maintenance is planning.

Unplanned or unscheduled maintenance is always going to occur – you can never eradicate

machine failures entirely – but companies that place a premium on planning for maintenance can limit downtime and create greater efficiencies and productivity.

And, in that same vein, forward-thinking companies that make use of technologies that keep people out of the line of fire when conducting maintenance can maximise workers’ safety and wellbeing.

It’s essential to establish a plan that responds to the maintenance needs related to the different activities that make up mining processes.

Elsewhere in this issue, we look at the recent Victorian Mine Rescue Competition, where teams from different mines came together to sharpen their emergency response skills and share their extensive knowledge.

We also take a look at a new pilot program launched by Rio Tinto, BHP and Fortescue that’s aimed at helping to eliminate disrespectful behaviours in the

COO CHRISTINE CLANCY

JOURNALIST ALEXANDRA EASTWOOD Tel: (03) 9690 8766 Email: alexandra.eastwood@primecreative.com.au

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JOURNALIST ASHLEY PERRY Tel: (03) 9690 8766 Email: ashley.perry@primecreative.com.au

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ART DIRECTOR Blake Storey GRAPHIC DESIGNERS Kerry Pert, Louis Romero

SAFETOWORK.COM.AU 3 JAN—FEB 2023

resources industry. Working in the mining industry can sometimes be tough, so it’s reassuring to see the majors taking steps to create a better working environment.

This month’s issue also examines industry regulators and provides a state-by-state breakdown of the different rules and regulations that govern the Australian resources sector and help to keep its workers safe.

Paul Hayes Managing Editor

FRONT COVER

Image: Nivek Industries

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In this issue 18

Features 16 Removing workers from the crush zone

Nivek Industries’ new, larger and more potent tracked elevating device – Big TED – is an essential piece of safety gear for maintenance personnel working on suspended load hazards.

team-based approach to maintenance

38 Work hard and breathe easy

that embraces safety while achieving

The protection of on-site workers is in

reductions in downtime.

Honeywell’s DNA, and the company has created solutions to safeguard lives in the

28 Remote workers are guarded by an Angel

Guardian Angel Safety delivers reliable

mining and construction industries.

40 Regulations around the country

integrated end-to-end network,

18 To the rescue

hardware and safety-monitoring solutions

The Victorian Mine Rescue Competition is an important opportunity for teams to sharpen their emergency response skills.

22 Avoiding the line of fire SafeGauge has developed an innovative range of diagnostic tools designed to remove technicians from danger.

26 Maintaining the Pit Viper is a team effort

Australia’s success in mining is

for the protection of isolated workers.

32 Going isocyanate-free to improve maintenance

underpinned by low rates of injury and loss of life, due in large part to the efforts of the various state and territory industry regulators.

A&I Coatings’ tough-wearing topcoat is an indispensable solution that improves safety for heavy machinery maintenance.

34 Your winners for the 2022 Prospect Awards

Safety was a key theme at the Australian

Epiroc’s drill rig is reinforced by a

Mining Prospect Awards.

38

42

REGULARS

3 COMMENT

6 NEWS

14 PRODUCTS

SAFETOWORK.COM.AU 4 JAN—FEB 2023

50 EVENTS

Regular health checks help prevent unplanned downtime

United. Inspired.

Avoid unplanned maintenance with RigScan from Epiroc Working hard in tough environments requires strength and endurance to keep your equipment running at peak performance in a safe way is key to a successful operation. RigScan is an advanced audit service product that gives you a real time, non-intrusive look at your equipment’s running condition and performance from the inside.

epiroc.com/en-au

News BHP workers safe following earthquake near Nickel West All BHP employees were safe after the miner temporarily lost communication with its underground workers at a mine site near Leinster, WA, following an earthquake.

Geoscience Australia reported a magnitude four seismic event struck near the Nickel West mine at a depth of 5km in the Goldfields’ region on November 23 2022.

A BHP spokeswoman said the earthquake resulted in a power outage and subsequent loss of communication with members of the Nickel West Leinster site underground team.

“All team members are safe, uninjured and accounted for,” she said.

“The safety of our people and operations is underpinned by our strong operating systems, technical monitoring procedures and the diligence and hard work of our teams.

BHP temporarily lost communication with its underground workers at a Leinster mine site following an earthquake.

“There is nothing more important than the safety of our people. In line with our usual processes, operations will resume once safety tests have been completed.”

The Australian Workers Union (AWU) urged WorkSafe and the company to release more details about the incident.

“BHP needs to give us the full story.

What happened? Will this happen again? Is it preventable?” Australian Workers Union state branch secretary,

Brad Gandy said according to Seven West Media. “Companies should be talking to us, talking to the relevant bodies – not closing ranks and bunkering down.”

Nickel West is a fully integrated mine-to-market business operating in various locations across WA. The integrated business adds value throughout the nickel supply chain, with the majority of Nickel West’s current production sold as powder and briquettes.

Attempt to activate dozer’s fire suppression system fails Inspectors from the New South Wales Resources Regulator recently investigated an incident and made a series of key safety recommendations when a dozer operator at an opencut mine unsuccessfully attempted to activate the machine’s fire suppression system.

The operator witnessed smoke and flames and tried to activate the fire suppression system, but the valve and panel cover separated from the mounting bracket when trying to withdraw the safety pin.

Unaware if the system could still be activated, the operator reversed a short distance, lowered the access ladder, and pressed the red emergency button.

With flames licking up through gaps

around the deck plate, the operator exited the cabin via the left-hand door and jumped from the deck about 3m to the ground.

The operator was not injured and went to the rear of the machine to shut down the engine down. The fire suppression system then activated automatically.

Following the incident, an assessment of the dozer was conducted by Resources Regulator inspectors, an industry safety and health representative and mine site representatives.

Where mines have rotary-style fire suppression system actuators, mine operators should undertake the following safety recommendations: develop a site standard for actuator

panel configuration; conduct an audit of plant to check all relevant fire suppression system panels are compliant; review the various types of fire suppression systems of activation to ensure all relevant personnel are trained; review instructional labels to ensure the information is correct; ensure that change-management processes identify appropriate actions; note differences between new plant systems and existing plant; review second egress methods and regularly train workers in their location and use; and report failures of safety critical systems to original equipment manufacturers (OEMs) to ensure they can address emerging issues with their designs.

SAFETOWORK.COM.AU 6 JAN—FEB 2023

B I G J U S T G OT B I G G E R

Comfortably handle weights of up to 3,000kgs, yet still maintains a low profile and manoeuvrability.

nivekindustries.com.au admin@nivekindustries.com.au 02 4937 6460

News Impact-sensitive explosives damaged during mine site delivery In a recent incident, a pallet of Class 1 explosives fell from the rear of a delivery vehicle while being unloaded at a Queensland mine site, resulting in Resources Safety and Health Queensland (RSHQ) issuing important safety guidelines.

As this was the third reported incident of this type in recent years, safety recommendations have been authorised by the Deputy Chief Inspector – Explosives at RSHQ, directing all relevant authority holders to review their systems to prevent future incidents.

Class 1 explosives are impact-sensitive,

and the effects of a fall could cause unplanned detonation or damage to the explosives.

In the most recent incident, the operator lost control of the pallet jack while manoeuvring a heavy pallet of detonating cord towards the rear of a light industrial during its unloading.

The pallet jack rolled under the weight of the pallet, falling 1.2m from the rear of the truck.

Work in the area ceased immediately and an exclusion zone was established while the volatile material was safely recovered.

Key safety recommendations include: authority holders reviewing their safety management systems; workers must be trained, assessed, and monitored to ensure they understand the control measures for the use of a pallet jack; that all training is effective; that hazards such as weight, gradient and visibility are identified; and that procedures for the transport and handling of explosives adequately address the manufacturers recommendations and that the Australian Code for the Transport of Explosives by Road and Rail is followed.

Electrical components fail on ammonium nitrate equipment Key safety recommendations have been circulated by inspectors from Resources Safety and Health Queensland (RSHQ) stemming from recent incidents of corroded electrical components.

In the first instance, damaged electrical components in the vicinity of ammonium nitrate product were subject to corrosion, with routine maintenance and pre-start inspections failing to identify and replace affected wiring, solenoids, actuators and switches.

A wiring harness with damaged insulation on a Mobile Processing Unit (MPU) bin lid actuator energised, resulting in a small fire.

MPUs are purpose-built vehicles that are used in mining operations to manufacture or blend Class 1 bulk explosives at the location of blasting.

In another incident, an internally corroded actuator energised and started a NAPCO ammonium nitrate emulsion (ANE) pump, while the mine re-load was unattended.

Where ANE pumps are inadvertently

activated, or where they fail to shut down, no-flow events introduce heat into the ammonium nitrate emulsion, generally under confinement.

This can lead to thermal decomposition of ammonium nitrate emulsion and an unplanned detonation event.

Key safety recommendations include: all fittings and components having a rating in accordance with

relevant standards; that workers using mobile and fixed plant/equipment should conduct thorough preoperational checks to ensure that external wiring, solenoids, actuators and switches are operational; and that preventive maintenance incorporates the testing and examination of electrical components subject to ammonium nitrate and emulsion exposure.

Recent incidents of corroded electrical components have prompted key safety recommendations.

SAFETOWORK.COM.AU 8 JAN—FEB 2023

SafeGauge has an innovative focus on technology that helps remove technicians from the footprint of heavy machinery.

Our SafeTest range of products offer wireless testing solutions that work up to 50m away so technicians stay clear from crush zones and out of the line of fire when live testing, ensuring worker safety, minimising Lost Time Injury (LTI) and reducing company liability.

To find out more about our live testing solutions visit safegauge.com.au.

Maximise Safety

8/31 Yilen Close, Beresfield NSW 2322 1300 222 392 safegauge.com.au

Eliminate Live Work

Wireless up to 50m

Purpose Built for Heavy Industry

News Australia’s new disability-inclusive job site launches Australians with disability now have more job and career opportunities than ever, with the country’s new disability-inclusive site, the Field.

The employment rate for people with a disability has not changed in over 28 years compared to those without disability, and today there are 4.4 million people who identify as having a disability, 2.1 million of which are of working age, with nearly half a million actively seeking work.

The Field is here to level up employment opportunities for everyone by removing the accessibility barriers often faced by people with disability in traditional employment platforms.

Businesses will have access to a range of practical support including an inclusive language tool that

assists employers to post disabilityinclusive job ads, and digital training resources to build capability and grow understanding when it comes to inclusive practices.

Employers will also promote and highlight their inclusive strategies and the accessible features within their workplaces, so candidates have more information and choice when applying for a job that suits their skills, experiences and accessibility requirements.

The Field also hopes to improve the recruitment experience for jobseekers, focusing on what people can do, rather than what they can’t.

Designed, delivered and led by people with disability, the Field provides equitable access to job-seekers, while simplifying

the recruitment process for employers.

“The Field will allow people with disability to present themselves to employers in a format they choose, with a choice to share their skills, accessibility requirements and preferences via text, video and audio options,” Australian of the Year Dylan Alcott said when launching the site.

“Not everyone with disability can work, and that’s okay. But for those that can, they deserve the right to choose if they do.

“Everyone deserves the right to employment. The Field is a groundbreaking digital job site that will open up a marketplace of talent with disability and level the playing field in the employment exchange.”

Upgrade supports growth of Gascoyne SES unit A Gascoyne State Emergency Service (SES) unit now has a new and improved headquarters following a $140,000 upgrade that will bolster its operational and training capabilities.

Useless Loop SES officially moved into its new facility following a handover ceremony with WA Emergency Services Minister Stephen Dawson and Fire and Emergency Services Commissioner Darren Klemm.

“A key part of supporting WA’s emergency services is to ensure our volunteers have access to modern facilities, enabling them to prepare and conduct their operations in the best possible environment,” Dawson said.

“We can’t take for granted the people who are prepared to drop everything at a moment’s notice and

put their lives on the line to protect their local community.

“These much-needed upgrades will not only make a big difference in how the Useless Loop SES train and respond to incidents, but also to build camaraderie within their own team and other emergency responders.

“This upgrade has been achieved through a successful partnership with the local community and businesses – and the Emergency Services Levy – to deliver a new collocated facility to support local volunteer response teams.”

The SES unit will share its headquarters with the Shark Bay Resources Emergency Response Team under an agreement with the Department of Fire and Emergency Services.

“The Shire of Shark Bay is busy area for travellers and tourists alike who

rely on the skills and experience of our emergency services volunteers to keep them safe,” Mining and Pastoral Region MLC Peter Foster said.

“This upgraded collocated facility is most welcome and enables our local volunteers to prepare and provide an even greater service to support their local community.”

SAFETOWORK.COM.AU 10 JAN—FEB 2023

WA’s Useless Loop SES has a new and improved headquarters.

Gladstone leads green methanol revolution Queensland Treasurer and Minister for Trade and Investment Cameron Dick has welcomed a Memorandum of Understanding (MoU) to further the commercialisation of methanol production by using green hydrogen in Gladstone.

Mitsubishi Gas Chemical Company (MGC) and Cement Australia (CA) will apply MGC’s newly developed Circular Carbon Methanol production technology to capture carbon dioxide from CA’s Gladstone Plant.

The Treasurer said the MoU is an important step on the journey towards the commercial production of green methanol.

“This joint feasibility study into the $150 million first-stage green methanol plant underlines the strong investment climate created by the Government’s $62 billion Queensland Jobs and Energy Plan,” Dick said.

“It also shows the array of potential opportunities for new and emerging industries to build a footprint in Gladstone.”

The Treasurer met with MGC representative director and president Masashi Fujii during his trade mission to Japan.

Phase one of the commercial operation is expected to start in

mid-2028 with a production capacity of up to 100,000 tonnes of green methanol per annum.

The Gladstone region is considered a prime area in which to develop businesses in a variety of renewable energy sectors. The are is ideal for growing a diverse green hydrogen sector with abundant renewable energy sources, existing infrastructure including port facilities, and a highly skilled workforce.

The green hydrogen economy is a priority for the State Government under its Queensland Hydrogen Industry Strategy.

Truro quarry fined over worker fatality A quartzite quarry operator located near Truro in South Australia and a labour hire company have been fined a total of $479,000 following the fatality of a worker in April 2020.

Kara Resources, trading as Hallett Resources Truro, and Taurus Recruitment both pleaded guilty in the South Australian Employment Tribunal (SAET) for breaches of the Work Health and Safety Act 2012.

A 29-year-old man suffered fatal head injuries when he entered a cavity of a rock crushing machine and attempted to remove a metal blockage at the quarry near Truro, about 100km north-east of Adelaide.

When the blockage was released, stored energy from within the machine caused its components to move under considerable force, striking the worker in the head.

No risk assessment or safe work

method was created for this hazardous task, and no training was provided to the worker in the removal of metal blockages.

SafeWork SA’s investigation identified that the risk of injury was foreseeable,and the incident could have been avoided had the company had adequate training and safe work procedures in place.

Taurus Recruitment failed to adequately consult, cooperate and coordinate with the host employer to ensure that adequate hazard identification and risk assessments process were in place.

It also failed to ensure that the host employer provided and maintained adequate safe work method statements and documented safe work procedures in relation to the safe operation and safe removal of metal blockages.

The SAET convicted Kara Resources and imposed a fine of $650,000 (reduced to $455,000

after a 30 per cent discount for early guilty plea) plus legal fees.

Taurus Recruitment, the labour hire company that employed the worker, was also convicted and fined $40,000 (reduced to $24,000 after a 40 per cent discount for early guilty pleas) plus legal fees.

In his sentencing comments, Deputy President Judge Rossi said the worker and his family were entitled to rely on Kara to adequately train and supervise him.

“He, his wife and their three young children were entitled to expect that after each shift of work he would return safely home,” Rossi said.

“At the same time, he and his family were also entitled to assume that Taurus, as his employer, would, insofar as was reasonably practicable, consult, cooperate and coordinate the activities to be performed.”

SAFETOWORK.COM.AU 11 JAN—FEB 2023

News Electric shock risks from incorrect wiring Following prosecutions by Western Australia’s Building and Energy, separate cases were recently heard at Perth Magistrates Court against a business and one of its employees, an electrical worker known as MJ, highlighting regulatory breaches and dangerous electric shock risks.

According to facts presented in court for both matters, Future Power was contracted in 2020 to connect the electricity supply for two communication huts in Shadforth and Broomehill West.

MJ carried out the work and Future Power submitted notices of completion

declaring that the installations were checked, tested, compliant and safe.

However, a Western Power electrical inspector later found the multiple earthed neutral (MEN) connection had not been installed at the Shadforth site.

Without an MEN, protective devices such as circuit breakers and fuses may not operate if an electrical fault occurs, which can cause metal objects to become live with lethal voltage levels.

At Broomehill West, the inspector found the switchboard’s active and neutral conductors were transposed, which could cause an electric shock

or fire. A non-compliant cable and connection method were also noted.

MJ was fined $8000 and ordered to pay costs of $537.15 after pleading guilty to four breaches of WA’s Electricity Licensing Regulations due to the substandard work.

Future Power also pleaded guilty to two offences under the regulations for submitting inaccurate notices of completion. It was fined $10,000 and had to pay costs of $418.

WA’s Director of Energy Safety Saj Abdoolakhan said the cases should remind electricians why checks and tests of their work are mandatory.

Pipe maker fined $45,000 after serious injury A Victorian company that manufactures reinforced concrete products has been fined $30,000 after a worker’s hand got caught in a machine at its Kilmore workplace, resulting in serious injury.

Reinforced Concrete Pipes Australia (RCPA) was also fined an additional $15,000 for failing to control the risk of a forklift colliding with pedestrians and other mobile plant.

The business also had to pay costs of $7560, with no conviction recorded.

The company was sentenced in the Ballarat Magistrates’ Court after earlier pleading guilty to a single charge of failing, so far as was reasonably practicable, to provide a safe working environment for persons other than employees, and to a single charge of failing, so far as was reasonably practicable, to provide a safe working environment.

In November 2019, a labour hire worker was tasked with cleaning a concrete precast machine. To carry out the task, workers were required to enter

the danger areas of the 40-tonne, 6m machine, descend 4m into a lower level and shovel concrete residue into a wheelbarrow for removal.

As the worker was lowered on a hydraulic platform his right hand became trapped between moving machine parts, resulting in the partial amputation of two fingers and the partial degloving of three fingers.

WorkSafe Victoria inspectors identified significant safety risks, including the risk of fall into the lower level by using the hydraulic platform rather than stairs to enter the lower level and exposure to multiple sheer and crush points.

The court heard RCPA had not carried out a risk assessment of the work, had not adequately trained the worker in the use of the plant, had not provided the machine’s manual to the worker, knew safety gate interlocks had been deliberately bypassed, and knew the machine could be turned on while workers were still inside the danger areas.

Upon reviewing CCTV footage and during inspections, WorkSafe Victoria inspectors also witnessed forklifts being driven in close proximity to pedestrians.

To manage risks when working with machinery employers should: • i dentify hazards, assess the risks associated with them and eliminate or control those risks by isolating them or using an alternative • t rain staff in the safe operation of machines and equipment and provide written procedures in the worker’s first language • d evelop and implement safe operating procedures in consultation with employees and health and safety representatives nsure safety guards and gates are • e compliant and fixed to machines at all times • r egularly service and inspect machines and equipment • p lace signs on or near a machine to alert employees of the dangers of operating it.

SAFETOWORK.COM.AU 12 JAN—FEB 2023

Products GUARDIAN ANGEL PORTAL LAUNCHES Guardian Angel Safety, an industry-leading provider of lone and remote work solutions in Australasia, has launched the Guardian Angel Portal to enable organisations to be more responsive to the changing safety needs of mobile workers working alone or remotely.

The portal allows customers to securely view and manage all safety devices, data, and planning for workers in real-time via an easy to-use interface.

In addition, all device-monitoring, vehicle-impact and rollover alerts are delivered to the portal – with an immediate response from Guardian Angel Safety if required.

The cloud-based portal encrypts data while being sent and at rest. In addition, policy-based permissions management ensures data can only be accessed by people who are authorised to do so within their role.

Guardian Angel Safety’s solutions circumvent the emergency number process and link customers to its response software at its graded monitoring stations with trained operators to speed up the emergency response for mobile workers working alone or remotely, including for sudden-onset injury or illness, road accidents, vehicle failure, or other emergencies.

• guardianangelsafety.co

VITRETHANE 650IF HAS A VIEW FOR SAFETY With an increased awareness of workplace health and safety when using protective coatings, A&I Coatings is continually looking for ways to reduce the risk of exposure to harmful chemicals, such as isocyanates in paint.

Exposure to isocyanates is known to cause respiratory illness and skin irritation, such as allergic contact dermatitis.

Utilising leading technology has led to a breakthrough in polyurethane coatings, with A&I Coatings formulating the first true isocyanate-free polyurethane coating available in Australia: Vitrethane 650IF. Vitrethane 650IF is a premium-quality two-pack isocyanate-free polyurethane topcoat. Utilising full polyurethane technology and curing without the use of isocyanates makes Vitrethane 650IF a safer and more durable coating than conventional isocyanate-free coatings.

Vitrethane 650IF is a high-gloss, versatile polyurethane topcoat with exceptional durability and weathering performance, and improved impact and abrasion resistance.

• aicoatings.com.au

SAFETYSPEAR PROTECTS WORKERS FROM UNDERGROUND HAZARDS Designed and manufactured by Rattlejack, the SafetySpear works to protect underground mining personnel and equipment from free-falling overhead hazards by plugging drill holes quickly and inexpensively with a lightweight, highimpact-absorbing polymer system.

The innovation addresses shortcomings of other practices in widespread global use, including corrosion-prone steel systems and traditional grouting and plating over where weaknesses can result in serious mine site injury and death.

The SafetySpear has been purpose-built to activate on impact with any downward force: its two-stage design decelerates the impact by blocking the hole with its flexible upper section, conforming to the shape and size of the available space. This effectively stops the falling hazard with minimal backward movement, a method never previously seen in underground mining.

rattlejack.com.au

SAFETOWORK.COM.AU 14 JAN—FEB 2023

THE NEXT STEP IN PRODUCTION DRILLING Epiroc has launched the Simba E70 S, a new long-hole production drill rig for medium-to-large-sized drifts.

While the Simba E70 S will provide customers with cutting-edge automation features and excellent drilling quality, it will also feature Epiroc’s optimisation method; a step-by-step program that continuously improves how the machine is utilised in the mining process.

“Our new Simba E70 S delivers greater value to our customers’ operations through improved productivity, with zero compromise on quality,” Epiroc sales and marketing and underground division vice president Sarah Hoffman said.

Simba E70 S is part of Epiroc’s smart series and can be delivered with the optional battery-electric driveline for reduced environmental impact and healthier underground conditions.

However, the real value is found while the machine is producing metres; the ability to track the Simba E70 S’s effectiveness and utilisation and produce metres when active is one of its main advantages.

• epiroc.com/en-au

DON’T LET DARKNESS STOP YOU The Atlas Copco HiLight B5+ Light Tower is suitable for a wide range of applications, including events, residential and road construction, temporary public lighting, and oil and gas requirements.

Designed to offer the widest choice when it comes to finding the light tower that is right for your application, the HiLight range provides a flexible and dynamic set of lighting options while addressing all aspects of efficiency. Safety operators can be assured of the robust build quality and compact size for which Atlas Copco is globally recognised.

Atlas Copco has put its innovation stamp on LED technology. The lenses in the LED light towers have a very special optic designed specifically for construction and mining applications.

This innovative, fully directional, LED lens design ensures the light coverage is maximised while a single HiLight tower can cover an area of up to 5000m2 with a 20 lux (brightness) average – ensuring a brighter, safer, and more productive site.

• atlascea.com.au

INTRODUCING THE SAFEGAUGE DIAL INDICATOR According to a 2019 Queensland Department of Resources report, 25 per cent of mining fatalities are related to interaction with machinery, which makes testing equipment extremely critical in ensuring safety and productivity.

In the past, testing heavy machines often required workers to be near the vehicle to manually take measurements, leaving them at risk of serious injuries.

Now with the SafeGauge dial indicator (DI), technicians can perform these tasks at a safe distance by enabling workers to remotely measure clearances, tolerances and wear on machine components safely, efficiently and out of the line of fire.

The SafeGauge DI connects via Bluetooth from a distance of up to 50m and measures up to 10mm of movement with an accuracy of 0.01mm. The DI unit is mounted on one machine component, with the pin resting on another.

The reading is ‘zeroed’ and the machine is run through the appropriate motions with the technician remaining at a safe distance. The SafeGauge MultiTool then displays the live reading between the two components in real-time to the technician, who is safely out of harm’s way.

• safegauge.com.au

SAFETOWORK.COM.AU 15 JAN—FEB 2023

Maintenance

Removing workers from the crush zone NIVEK INDUSTRIES’ NEW, LARGER AND MORE POTENT TRACKED ELEVATING DEVICE – BIG TED – IS AN ESSENTIAL PIECE OF SAFETY GEAR FOR MAINTENANCE PERSONNEL WORKING ON SUSPENDED LOAD HAZARDS.

W

hen Kevin Cant narrowly avoided serious injury while conducting routine maintenance back in 2008, he realised the traditional way of doing things could stand to improve.

Cant was placed in harm’s way as a result of a belly plate slipping and falling from a dozer, and over the next three year he undertook detailed research and concept design and ultimately developed the first tracked elevated device (TED) prototype in 2011.

That same year saw the launch of Nivek Industries, an Australianowned manufacturing and fabrication company that prides itself on quality products utilised in mine and industrial maintenance applications.

Safety in the workplace is paramount, especially when working around heavy machinery, and the outcome of an incident is usually catastrophic. Kevin understood that the old methods of removing mobile plant components such as belly plates – a difficult, dangerous, and time-consuming task involving hoists, slings and chains – was no longer acceptable.

Nivek’s TED is a self-propelled belly plate jack designed to take the weight out of belly plate extraction and replacement while removing personnel from suspended load hazards, safeguarding against potentially fatal crush injuries.

Big TED incorporates remote-control operation, all-terrain capability and low profile.

“TED enables the safe removal of machinery components by removing the suspended load hazard and transferring the manual handling element onto the TED,” Kevin’s brother and Nivek general manager Derrick Cant told Safe to Work.

The device incorporates several key design features, including remote-control operation, all-terrain capability, and low profile. It is also easily adaptable through the use of its ever-expanding range of practical attachments designed to increase the safety, efficiency and reliability of worksite operations.

TED can make myriad maintenance jobs safer and less physically stressful for technicians and other personnel, reducing

planned maintenance times and driving cost-efficiencies.

“TED fundamentally improves the safety and working conditions of maintenance personnel using the TED, when either deployed in the field or in workshop,” Cant said.

Big TED is a new a larger version that features an expanded capacity to move heavier loads. The bigger unit can comfortably handle weights up to 3000kg, while maintaining a relatively low profile and enhanced manoeuvrability.

“We’ve received strong interest from the market for a bigger version of the TED and that’s been the motivation to make the Big TED, especially for clients with specific maintenance requirements,” Cant said.

SAFETOWORK.COM.AU 16 JAN—FEB 2023

“Due to its increased lifting capacity, we envisage Big TED being used primarily on fixed plant maintenance tasks, or in conjunction with heavy mobile machinery and mining equipment,” Cant said.

“Essentially, it is a mobile scissor lift that can be easily modified by way of attachment to suit a wide variety of specific needs.”

The drive system, comprising two independent 3.5kW infinite control electric drive motors, is controlled by a proportional joystick on the remote control. Not only do the motors provide sufficient torque to carry the heavy loads across any terrain, the machine is also extremely responsive and operator friendly.

The 24V, 448Ah rechargeable battery system provides operators with at least two hours of continuous operation.

“We have taken all the feedback received over the years from customers using TED and have incorporated many of the features into the Big TED design,” Cant said Some additional features of Big TED include remote-controlled side shift, powered turntable and AUX (auxiliary port) functionality to enable the utilisation of smart attachments.

The machine also has built-in load cells to measure the load and a tilt sensor to ensure it is operating within design parameters.

The range of smart attachments for Big TED help take the weight out of heavy maintenance tasks.

Big Ted and TED.

“Attachments for the Big TED can be designed and manufactured to the client’s specific requirements.”

Cant said.

A large resources organisation recently embarked upon a trial of the Big TED, aiming to improve safety and efficiency in a challenging operational environment.

The Big TED was utilised in the removal and installation of large vessels (digestor pots) undergoing scheduled maintenance, a time- and labour-intensive activity that can be difficult and dangerous.

The use of Big TED significantly increased workers’ ability to undertake their maintenance in a safer way, while halving the time it usually takes to complete the task.

Due to its increased load-bearing capacity and functionality, Big TED is being trialled on other maintenance

tasks by the same organisation, also making traditionally difficult-tocomplete maintenance safer, easier and more efficient.

Designed by a fitter, for fitters, the TED and Big TED are becoming widely sought-after among both workers and management throughout the mining industry.

Cant and his team at Nivek seek to provide a tailor-made solution based client requirements, and their willingness to embrace feedback has led to ongoing improvements to the TED and its range of attachments.

“We are committed to creating innovative products for heavy industry that enhance workplace safety and efficiency,” Cant said.

“With attachments designed in all different shapes and styles, the range of tasks that Nivek’s TEDs can complete is endless.

“We have attachments designed for general maintenance, as well as more specific jobs on Liebherr Ultra Class, Caterpillar, Hitachi, Komatsu, LeTourneau, Terex and many other types of machinery.

“Whether you’re working on haul trucks, dozers, graders, scrapers, service carts, push carts, water carts or any other heavy machinery or fixed plant, TED or Big TED and the tailored attachments provide a stable base to safely conduct maintenance from.”

SAFETOWORK.COM.AU 17 JAN—FEB 2023

Mine rescue

To the rescue

Firefighting is among the major events in competition.

THE VICTORIAN MINE RESCUE COMPETITION IS AN IMPORTANT OPPORTUNITY FOR TEAMS TO SHARPEN THEIR EMERGENCY RESPONSE SKILLS.

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ine rescue is a highly specialised job, one that requires teams to save trapped and injured miners, fight fires, and respond to all other kinds of emergencies.

These teams need to assess and manage risk to ensure workers’ safety above and below the ground.

And given the potential dangers that perpetually exist on a mining operation, it’s vital rescue teams are well trained and always at the top of their game.

The Victorian Mine Rescue Competition (VMRC) – organised by the Mineral Council of Australia (MCA) Victoria Division, a professional body engaged in representing the interests of member companies operating in, exploring and providing services to the minerals industry in the state – is one of the best opportunities to put those skills to the test.

Running since 1993, the VMRC sees rescue and emergency response

teams from various mines around the country competing in a variety of simulated situations, putting their skills to the test and sharing their extensive knowledge with one another.

The 2022 event was held near Bendigo, north-west of Melbourne. It featured eight competing in a range of events, including team skills, firefighting, first aid and rope rescue, as well as a search-and-rescue scenario conducted at Agnico Eagle’s nearby Fosterville gold mine and ISH 24’s safety training facility.

“The scenarios are designed to be as realistic as possible, with actors performing the role of injured workers, featuring highly realistic wounds in a real-world simulation,” MCA Victorian executive director James Sorahan told Safe to Work.

“They are very intense and quite confronting scenarios; however, we need to make them as real as possible in order to apply pressure, ensuring teams receive the most effective

training so as to be able to react effectively if confronted with a similar scenario in a real-life situation.”

While the competition between the teams can be intense, everyone is happy to share rescue knowledge related to their areas of expertise, embracing the opportunity to learn new skills from their peers.

“The event seeks to achieve to important outcomes,” Sorahan said.

“Firstly, it’s a training exercise, and this dimension is of deep value for the participants.

“Secondly, there is the competition element, whereby scoring and related information, including detailed reports outlining key performance metrics and insights into effective responses, are passed onto teams for further improvement.”

The competition is a critical part of the industry’s efforts to support highly trained rescue personnel across Australia, significantly contributing to the sector’s commitment of zero harm.

SAFETOWORK.COM.AU 18 JAN—FEB 2023

The VMRC sees teams putting their skills to the test.

“Emergency mine rescue teams are comprised of volunteers – they could be anyone from a geologist to a truck driver – so this form of training exercise is vitally important to the development of competencies for individual members, as well as fostering team cohesion,” Sorahan said.

Emergency response agencies attended the competition, helping rescue personnel and first responders build capacity in the event in which they are called upon to assist in an emergency.

The categories throughout the competition allow for the different types of expertise, providing teams an opportunity to excel.

“For many years there were two competitions, one for underground mine rescue and another for surface mines,” Sorahan said.

“But a few years ago they brought them together into just one competition.

“It’s great exposure for teams to learn about and experience the various sorts of emergency situations that can arise at different types of mines.

Exposing people to training for different types of mines is also

beneficial if they move to a site with unfamiliar emergencies.

The hands-on experience in the competition is supported with feedback from a team of adjudicators, who assess the competitors’ every move.

“One of the major aims of the competition is to bring together emergency response agencies in order to create that important dialogue between mine rescue teams and emergency responders,” Sorahan said.

“There are a range of emergency services that need to work together alongside mine rescue teams, so it is incredibly useful for the mine rescue teams to learn from other emergency agencies.

“For example, we have the CFA team from Bendigo compete along with a contingent from Victoria Police and members from Ambulance Victoria, and bringing these emergency responders together is vitally important.”

The competition doesn’t just better prepare mine rescuers, but also provides realistic training

Actors are hired to perform the role of injured workers.

SAFETOWORK.COM.AU 19 JAN—FEB 2023

Mine rescue Victorian Mine Rescue Competition winners The team from Mandalay Resources’ Costerfield mine in Victoria took out overall honours, followed by CFA Oscar 1 Technical Rescue and CMOC Northparkes.

Full results: Overall 1st: Mandalay Costerfield 2nd: CFA Oscar 1 Technical Rescue 3rd: CMOC Northparkes

Scenarios throughout the competition are designed to be as realistic as possible.

“They are very intense and quite confronting (training) scenarios. We need to make them as real as possible in order to apply pressure ensuring teams receive the most effective training.” opportunities for emergency service workers.

“We’re really happy this competition provides an opportunity for some of the volunteers.”

The competition also gives local communities peace of mind that the mines operating on their doorstep are safe.

It’s not all serious, though. The competition finishes on a fun note with a team-building exercise.

“The Spence Herd challenge is a fun exercise at the end of the long weekend. Teams compete with each other in team-building tasks and they really look forward to it,” Sorahan said.

“The point of it is training, but being a competition certainly adds a fun element to it and is also as a key motivator for success.”

With the chance to be competitive, meet new people and bring pride to their mines, the MCA reinforces the simple but important message of the VMRC. “Every worker deserves to go home safely, and mine rescue teams take any form and amount of training extraordinarily seriously,” Sorahan says.

“You hope that they don’t ever need to use the skills they learn in the competition, but at least they are ready if something does happen.”

SAFETOWORK.COM.AU 20 JAN—FEB 2023

Winning team captain Owen Shay of CFA Oscar 1 Technical Rescue Winning team – overall safety Mandalay Costerfield Fire exercise 1st: Mandalay Costerfield 2nd: Agnico Eagle Fosterville 3rd: CMOC Northparkes First aid 1st: Mandalay Costerfield 2nd: CMOC Northparkes 3rd: Agnico Eagle Fosterville Ropes exercise 1st: CFA Oscar 1 Technical Rescue 2nd: Mandalay Costerfield 3rd: CMOC Northparkes Underground search and rescue 1st: CFA Oscar 1 Technical Rescue 2nd: Mandalay Costerfield 3rd: CMOC Northparkes Skills exercise 1st: CFA Oscar 1 Technical Rescue 2nd: Ballarat Gold Mine 3rd: Mandalay Costerfield Theory 1st: Mandalay Costerfield 2nd: Agnico Eagle Fosterville 3rd: Cadia Valley Breathing apparatus 1st: CMOC Northparkes 2nd: Cadia Valley 3rd: Mandalay Costerfield

ISSUE 22 -

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Maintenance

Avoiding the line of fire SAFEGAUGE HAS DEVELOPED AN INNOVATIVE RANGE OF DIAGNOSTIC TOOLS DESIGNED TO REMOVE TECHNICIANS FROM DANGER WHEN COMPLETING THE LIVE TESTING OF HEAVY MOBILE EQUIPMENT.

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ome of the simplest tools are the most powerful.

In the case of SafeGauge, the company has designed exactly these kinds of tools to eliminate the chances of technicians being severely injured when completing live testing on heavy mobile plant machinery.

SafeGauge founder Luke Dawson routinely tested machinery across a variety of mine sites during his time working as a heavy plant mechanic.

He was concerned that workers were regularly exposed to the unnecessary risk.

“I felt there was a need to improve the safety outcomes for technicians servicing mobile equipment, and in

SafeGauge tools keep technicians out of the ‘line of fire’.

doing so have a positive impact on the mining industry,” Dawson told Safe to Work.

“There’s been far too many fatalities and serious injuries on mine sites, or in workshops, simply through technicians doing their job.

“The risk involved with human and machinery interaction has always been significant, and although many of the maintenance tasks are routine the dangers are ever-present, so I really wanted to remove technicians from those dangerous zones and, in essence, eliminate that safety risk.”

To that end, Dawson commenced research and development on a specialist wireless testing solution that would enable technicians to monitor

and test heavy mobile plant machinery from a safe distance.

“My initial idea was to develop a wireless transducer, connected via Bluetooth and with a transmission distance of up to 50m, in order to complete steering and brake pressure calibrations,” Dawson said.

“In the past, a technician would have to plug a mechanical pressure gauge connected through a highpressure hose into different parts of a machine or hydraulic system in order to complete the test, and in doing so would place themselves in unsafe, potentially dangerous positions.

“By utilising a wireless transducer such as the smart pressure transducer (PT) developed by SafeGauge, a

SAFETOWORK.COM.AU 22 JAN—FEB 2023

technician can complete the same diagnostic test from the same ports once used with a hand-held pressure gauge, but now at a safe distance from the machine or equipment.

“Essentially, the requirement to hold a high-pressure hose in an unsafe spot to complete the pressure test has been removed.

“Previously, you would have to stop and start the machine or equipment in order to place the gauges on different parts to test different systems, and you’d need to be physically connected to the machine, completing one test at a time.

“Now, with SafeGauge’s solution, multiple tests can be completed simultaneously and safely by utilising several PTs connected to the Wireless MultiTool (W-MultiTool), with the technician far from the crush zone.”

The development of a dial indicator (DI), also utilising a Bluetooth connection from up to 50m away, was the next diagnostic tool that would remove the requirement for a technician to read a physical dial while the plant was live.

SafeGauge has now produced the multi-award winning SafeTest range

SafeGauge tools are developed to enable technicians to monitor machinery from a safe distance.

of PTs and DIs, developed for heavy industry applications.

A SafeTest PT Series kit consists of two, four, six or seven PTs, plus the W-MultiTool and charging case. The kit is suitable for measuring gas or fluid in a variety of pressures.

SafeTest tooling functions from up to 50m away, allowing workers to stay clear from the crush zones and line of fire when live testing.

The PT connects to the W-MultiTool, which displays the live pressure readings, has a battery life of more than 20 hours, and is easily recharged using the rugged case.

Using the SafeTest MultiTool enables up to seven PTs to be tested and displayed on the device. Each connected tool has an option for a customised title, and customised software for the W-MultiTool is also available. SafeGauge can provide tailored solutions for specific customer requirements.

The latest PT Series comes with an improved design based on in-field use and customer feedback, and includes an improved rugged dual-layer housing, shock-proof silicone outer protection, an auto-sealing charging

The SafeTest tachometer series enables wireless measurement of revolutions per minute.

slot for increased water resistance, and a customisable labelling system for greater flexibility.

There are various pressure range options, including 25 bar, 100 bar, 300 bar and 600 bar.

The SafeGauge DI is a Bluetooth device designed to measure displacement within 0.01mm. With Bluetooth connection from up to 50m away, technicians retain the ability to complete maintenance safely and more efficiently.

“With the requirement to measure wear on large pins and bushes on various parts of the frame of a machine, the DI is also designed to move the technician away from crush areas while testing is underway,” Dawson said.

“In the past, the technician would have to be positioned close enough to be able to read a mechanical dial fixed to different parts of the machine.

“The SafeGauge DI ensures the technician can now undertake this task remotely, as the wireless transmission technology keeps the technician clear of the machinery and any exposure to potential dangers.”

DI Series kits are available in one, two and four channels, as well as a customised kit option, and are supplied with everything needed to set up and conduct testing, including high-quality mag bases.

The SafeTest FS3 series kit consists of two PTs, one DI, the W-MultiTool and a charging case, making it

SAFETOWORK.COM.AU 23 JAN—FEB 2023

Maintenance

SafeGauge utilises fully wireless measuring tools.

the perfect all-in-one kit for rapid breakdown response crews and field service teams.

Packaged in a compact hard-shell carry case, and with built-in charging harness, the SafeTest FS Kit is ready to go at a moment’s notice.

The SafeTest tachometer (TM) series enables completely wireless measurement of revolutions per minute (RPM), removing technicians from the live work area while measuring the speed of fans, pumps, drill heads and other rotating machinery components.

“A technician was previously required to stand in front of a fan, often 3m in diameter and spinning at 2000–3000RPM, operating a handheld tachometer in order to measure the fan speed,” Dawson said.

“In this instance, the technician is exposed to potential projectiles coming off the fan, exposed to failure of the fan, while being physically located on the machine, in the line of fire and unseen by the operator as the machine is running.

“The SafeTest TM has the capability, via Bluetooth, to accurately read fan speed from the operator’s cabin, further removing the technician from any form of potential harm.”

This rugged non-contact laser tachometer is designed to achieve fast, accurate measurements in the harshest mining environments while out of harm’s way, and the use of the W-MultiTool captures multiple RPM measurements at the same time.

Various mounting options enable complete flexibility for every application.

SafeTest TM series kits are also available in one-, two- or fourchannel kits.

Using the W-MultiTool enables up to seven SafeTest products to be connected and displayed on the device, and each PT has an option for a customised title of your choice for each specific test.

In the mining industry, safety remains the number-one priority, and with a range of innovative solutions for hydraulic testing and maintenance, SafeGauge delivers enhanced safety along with faster, more efficient testing across a wide range of mobile plant.

The added flow-on benefits include reduced downtime and more productive operating hours, with SafeGauge products specifically designed for haul trucks, excavators and shovels, dozers, drill rigs, graders, and loaders.

Dial indicators can use a Bluetooth connection from up to 50m away.

At the recent 2022 NSW Mining Industry and Supplier Awards, SafeGauge received the top gong, winning the Small Business of the Year.

This award recognises the hard work and achievement of Dawson and his team at SafeGauge, as well as the valuable contribution their products are making to the safety of workers within the Australian mining industry.

“We’re a small company with a talented and growing team, and this recognition means a lot to all of us,” Dawson said.

“A snapshot of the near future will see SafeGauge focused on software development and the capturing and reporting of data from our smart tools.

“We are also focused on growing the business internationally, into both the North and South American markets.

“Our product development is all about increasing the safety for technicians and we will continue to work closely with our customers to both better understand the issues they face and determine what tools we can develop to meet their requirements.”

SAFETOWORK.COM.AU 24 JAN—FEB 2023

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Subscribe to Australian Resources & Investment to stay up to date with the latest news on ASX-listed mining stocks and commodity prices.

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Maintenance

Maintaining the Pit Viper is a team effort EPIROC’S DRILL RIG IS A ROBUST AND RELIABLE PIECE OF EQUIPMENT, REINFORCED BY A TEAM-BASED APPROACH TO MAINTENANCE THAT EMBRACES SAFETY WHILE ACHIEVING REDUCTIONS IN DOWNTIME.

The PV-271 can be configured with an extra capacity package, boosting its bit load capacity.

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piroc’s Pit Viper series of drill rigs is highly regarded in the global resources industry.

Pit Vipers are renowned as safe, flexible and cost-effective blasthole drilling machines that are extremely efficient, productive and, with rigorous planned maintenance, incredibly safe.

Epiroc’s machines are built in stateof-the-art facilities, and the high-quality fabrication ensures the capacity to last through multiple re-powers.

The PV-271 can operate in almost any surface mining application, whether it is gold, copper, coal, iron ore or silver, and is regarded as the drill that put the Pit Viper on the map.

The drill rig is available in diesel or electric and is automation-ready, which means system upgrades and addons can be completed without major machine rebuilds. It is equipped with a standard Rig Control System (RCS) operating platform, setting a high bar for efficiency and productivity.

Now in its fifth generation, Epiroc’s RCS platform is the foundation of Pit Viper automation. RCS 5 has an enhanced control hub with improved usability, allowing operators to switch seamlessly between screens in a well organised and dynamic manner.

The new drilling data screen on the RCS 5 features real-time depth monitoring, while operators can now

create and edit drill plans on-board or from a remote location quickly with the drilling plan manager.

Critical maintenance is completed through a flexible approach, with major componentry placed within a module – effectively a frame – that can easily be inserted into the Pit Viper upon the removal of ageing components.

“On that frame is the engine, drive train, compressor, pumps and fire suppression equipment, essentially the heart of the machine,” Epiroc’s national service operations manager – parts and services Steven Hayes told Safe to Work.

“The way the PV-271 has been manufactured has made it easy for us to create these modules for significantly

SAFETOWORK.COM.AU 26 JAN—FEB 2023

shorter periods of planned maintenance, resulting in significant uptime.

“The modules are pre-built in a workshop environment before being transported to site, where a brief shutdown occurs. The old module is removed and the new module inserted.

“The beauty of this approach is that it removes the requirement for an extended period of on-site maintenance, where the harsh and sometimes unstable environment of the Pilbara can lead to unforeseen problems and delays.

“This approach is fundamentally safer and faster, as the Pit Viper is offline for a minimal amount of time.”

The PV-271 can be configured with the XC (extra capacity) package, boosting its bit load capacity from 34 to 42.5 tonnes.

In October, Epiroc announced it had won a large equipment order from CITIC Pacific Mining, with a fleet of automated PV-271XC rigs to be used at the Sino Iron open-pit mine in the Pilbara region of Western Australia.

The drills bound for CITIC Pacific Mining will feature Epiroc’s exclusive autonomous drill plan execution (ADPE) technology, a unique feature in that it enables the rigs to complete full drill patterns rather than single rows.

The PV-271XC drills will also be installed with AutoDrill, which allows for up to 100 per cent of the drilling cycle to be in automatic mode. This is alongside AutoLevel, which minimises the time it takes to level and de-level, enabling more drilling time in the process.

“If any component doesn’t meet expectations or fails on the PV-271, we have a dedicated team located in Newman (in the Pilbara) supporting mining operations,” Hayes said.

“We can move quickly to undertake any unplanned repairs or servicing as required or, alternatively, provide the necessary support and expert advice to our customer’s on-site maintenance personnel.”

Critical maintenance on the PV-271 is completed via a modular approach.

The PV-270 series of drill rigs also includes the 275 model, which has become a staple for its capability in coal overburden drilling and hard rock applications like copper and iron ore.

The original Pit Viper – the PV-351 – offers 56.7 tonnes of bit load capacity, making it the most powerful drill rig in the Pit Viper range.

While Epiroc can offer diesel and electric options for the Pit Viper, more and more customers are opting for the zero-emission route.

There are now 116 electric PVs globally, split between Latin America, Africa, Europe and North America.

Recent orders by Tier 1 mining companies highlight the global reputation of the PV range, and the increased electric push of the drill rigs reflects Epiroc’s broader decarbonisation strategy.

Epiroc has become a market leader in automation, digitalisation and electrification solutions.

The company places a premium on safety, achieved through a sophisticated approach to the maintenance and servicing of mining machinery such as the Pit Viper series of drill rigs.

Whether scheduled maintenance or unplanned repairs, Epiroc’s dedicated professionals understand the machinery and are dedicated to ensuring it is fully operational.

“Completing maintenance via a modular approach means that when the major components on the PV271 reach their 20,000 hours of service, everything gets changed at once,” Hayes said.

“Essentially, it’s the equivalent of resetting the machine and with Epiroc’s quality control we’re confident the machine is able to perform its next 20,000 hours without the requirement for significant maintenance-related downtime.

“Before utilising a modular approach to undertaking planned maintenance, a great deal of perceived pressure would impact upon maintenance teams as they felt they had to complete a significant amount of work on-site over a relatively short period of time.

“The impending deadline to complete the work would create undue pressure and lead to safety issues.

So what would once take 12 days to accomplish can now be completed in three or four days.

“Today, the pressure is on the maintenance team to install just the one module and once completed the PV271 Pit Viper can quickly re-commence operation, demonstrating superior reliability and productivity, ultimately contributing to the lowest total cost of ownership in the blast hole drilling industry in its class.”

SAFETOWORK.COM.AU 27 JAN—FEB 2023

Maintenance

Remote workers are guarded by an Angel GUARDIAN ANGEL SAFETY DELIVERS RELIABLE END-TO-END NETWORK, HARDWARE AND SAFETY-MONITORING SOLUTIONS FOR THE PROTECTION OF LONE WORKERS.

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one workers are considered those who work by themselves or in the community with only limited support arrangements, exposed to risk by being isolated from the usual back-up support.

The potential risk of any serious injury from existing hazards is increased in these unique working environments, and such a situation requires additional precautions.

A major danger for remote or isolated workers is sustaining an injury that precludes self- rescue, such as overnight or during weekends or holidays, where assistance from other people may be limited.

Guardian Angel Safety’s founder and chief executive officer Petra Håkansson is passionate about the need to establish and maintain the safety and security of isolated workers engaged in various activities, often in remote settings,.

With more than two decades spent working with an array of emergency communications technologies, principally GPS-based systems, Håkansson has extensive experience in the research, development, and implementation of tailored emergency monitoring solutions, as well as the regulatory landscape that employers are required to meet.

“We now provide critical response solutions to 30 per cent of all New Zealand councils, the country’s primary workplace health and safety regulator, WorkSafe, as well as Suncorp Group in Australia,” Håkansson told Safe to Work.

“Currently, we have a series of pilot programs underway with councils across Australia and our EVERYWHERE solution, a global situational awareness platform utilising Garmin and Iridium devices as well as the Iridium satellite constellation, Wi-Fi and cellular networks, is deployed extensively across the Australian mining industry.”

The company recently launched the Guardian Angel Portal with the aim of creating a more responsive, flexible and secure operational approach to the everchanging safety requirements of solitary and remote workers.

The new portal enables the ability to securely view and manage all safety devices, data and planning for workers in real-time via a simple and intuitive interface with the ability to send immediate notifications to the most appropriate emergency services.

“Our portal provides our clients with a single source of aggregated information, enabling them to efficiently monitor and manage their workers,” Håkansson said.

The 24–7 real-time monitoring feature embedded in the Guardian Angel Portal results in a trustworthy end-to-end remote safety solution that ensures employers can deliver a high duty of care for the safety of their workforce.

“Connectivity and productivity are amplified, with our clients able to securely view and manage all safety devices and systems in real-time and in one place, including satellite devices, smartphone applications, cellular

pendants, vehicle impact and rollover alerts, many location-based services, and APIs (application programming interfaces),” Håkansson said.

“The portal is hardware-agnostic, ensuring we can leverage new safety devices and technology innovations, providing our clients with the most upto-date safety solution based upon their specific requirements.”

Workers’ ability to make contact with support services is vitally important, particularly in cases of emergency, and a robust and trustworthy communications system is required to do so in a reliable way.

The type of system chosen will depend on factors such as the distance from ‘home base’, the environment in which the worker will be located or through which they will be travelling (ie the terrain), expected environmental conditions, and access to power (to recharge batteries).

SAFETOWORK.COM.AU 28 JAN—FEB 2023

Guardian Angel matches risk and environment to its most appropriate hardware and processes.

The expansive nature of mines means workers need reliable contact networks.

Expert advice and local knowledge may be needed to assist with the selection of an effective communication system.

“We’ve designed our portal to be very flexible so customers can add new devices and solutions any time, regardless of manufacturer, as their safety needs change,” Håkansson said.

“Within an organisation, people can be assigned to any monitored devices, able to be easily shared among different teams, with a tailored incident response solution.”

With all user and escalation contact details in one place, Guardian Angel Safety’s monitoring stations always have the latest response instructions for any device or user.

“Any changes made via the portal – for instance, a device is moved between workers – are monitored and instantly updated within the system, at the same time establishing an auditable data trail,” Håkansson said.

“We’ve created a highly intuitive system, reducing the potential for human error, as clients are no longer required to manually update spreadsheets from device manufacturers or forward them to us to make changes.”

Data sent to the cloud-based portal is fully encrypted and policy-based permissions management ensures the information can only be accessed by authorised employees.

Guardian Angel Safety’s solutions circumvent the emergency number process and link customers to its lowlatency response software.

The company’s A1-graded monitoring stations are staffed by trained operators who ensure a timely response.

Guardian Angel Safety is committed to the ongoing development of its portal, welcoming feedback to meet employers’ health and safety laws and security requirements throughout Australasia and the Pacific.

To enable further integration, Guardian Angel Safety can also provide access to an API key and sandbox testing environment, allowing customers to connect their HR software to maintain their users and escalations automatically.

Håkansson said the portal would provide a valuable opportunity to collect industry insights on emergency or safety-related incidents through anonymised data collection and retention.

“We work with a wide range of organisations with remote and mobile workers, including government agencies, regional councils and environmental organisations; finance, banking and insurance; health boards and mobile community health providers; and forestry, mining, farming and agriculture,” she said.

“Our portal creates a unique opportunity to assist our clients further from a risk and prevention standpoint,

as we’ll be able to analyse data to gain insights into why and where incidents are happening.”

Good practice for managing remote workers includes having a communication schedule between the worker and someone able to raise an alarm if the worker fails get in touch.

Guardian Angel automates this function using scheduled welfare checks in the solution, which pops up asking the worker to confirm they are okay at chosen intervals. If they fail to respond, a “failed welfare check” goes through to the monitoring station where the operators will follow the client instructions and co-ordinate a response.

A policy on frequency of contact, and the action to be taken if contact is not received, should be developed and provided to all relevant workers. This could also include family members as a point of contact, other organisations in the area, and community leaders if they are able to raise the alarm.

Procedures developed should be tested, a process that can be configured through the Guardian Angel Portal and updated as required.

“Having the right safety solutions for lone and remote workers is all about planning for unforeseen situations and ensuring the appropriate response,” Håkansson said.

“The protection of employees’ physical safety will lead them to feel psychologically safer and happier in their workplace, and in this way Guardian Angel’s solutions fundamentally contribute to an organisation’s compliance with the ‘S’ in ESG (environmental, social and governance).

“We are striving to be the gold standard in the provision of protection for mobile workers operating alone or in remote and isolated environments across Australasia, not for financial gain but to implement safety solutions that will absolutely deliver peace of mind and real safety outcomes.”

SAFETOWORK.COM.AU 29 JAN—FEB 2023

Maintenance

Going isocyanate-free to improve maintenance performance A&I COATINGS’ TOUGH-WEARING TOPCOAT IS AN INDISPENSABLE SOLUTION THAT OFFERS IMPROVED SAFETY FOR HEAVY MACHINERY MAINTENANCE.

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aintaining the reliability of equipment remains one of the most important considerations on a functional mining operation, almost indistinguishable from the need to ensure the health and safety of the workforce.

Corrosion remains a constant threat to equipment, plant and infrastructure across the resources sector. And that corrosion is often encouraged by environmental or chemical conditions that come from operating amid harsh surface conditions or deep underground.

The quality and functionality of equipment is crucial to successful mining and the requirement for consistent and efficient maintenance is vitally important.

Major rebuilds and ongoing repairs remain critical to the sustainability of machinery, and a key consideration for effective maintenance remains the suitability of paint for the protection machinery surfaces.

“We have engineered the optimum formula, ideally suited to the harsh environment of the Australian mining industry,” A&I Coatings business development and customer satisfaction manager Bill Chesterfield told Safe to Work.

With decades of experience engineering polyurethane coatings

for mining equipment, A&I Coatings is consistently providing the local and global market with leading paint solutions for heavy plant and machinery.

In many applications where machinery needs to be painted, safety is paramount. It is essential that maintenance workers are not exposed to harmful chemicals such as isocyanates.

“Over the last 18 months our research and development team have been developing the first

isocyanate-free polyurethane coating, called Vitrethane 650,” Chesterfield said.

Utilising patented technology, Vitrethane 650 is considered a breakthrough in the coating industry.

With a quality-control system run

by A&I Coatings, the new product complies with ISO 9001: 2015 and is a registered manufacturing unit with the Australian Paint Approval Scheme. It represents a significant advancement in protective coatings, specifically topcoats used for

It is essential workers are not exposed to harmful chemicals such as isocyanates when maintaining equipment.

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new builds, major repairs and the ongoing maintenance of surface and underground mining gear.

This new technology completely removes the risk of exposure to isocyanates found in polyurethanes.

This results in a safe and environmentally friendly coating that provides zero exposure to harmful chemicals during application while retaining the hard-wearing and maintenance-friendly characteristics of an isocyanate-cured polyurethane.

A&I Coatings has engineered Vitrethane 650 to be more durable and more sustainable than traditional isocyanate-free coatings.

Many companies are using enamels, catalysed acrylics, or modified epoxies to reduce workplace harm; however, these coatings can be brittle and often have poor impact-resistance.

These coatings are also said to be less able to withstand atmospheric elements such as acid-rain, salt sulphates, or ultraviolet (UV) exposure, all of which can lead to an early breakdown of the coating and, in turn, expose the machinery to corrosion and increase maintenance costs.

In some cases, this may lead to a shortened machine lifecycle or a reduction in its ability to function properly.

“As these coatings break down, the integrity of the paint and the substrate is affected,” Chesterfield said.

Mining haul trucks are a classic example of equipment where the body of the machine is often subject to scrapes and impacts.

“Modified epoxy and catalysed acrylics are examples of commonly used coatings that retain poor reverse impact (resistance), typically shattering and deaminating on the exterior of machine bodies caused

by the impact of rocks or other hard materials falling into the tray,” Chesterfield explained.

Compared to current coatings used on mining equipment, Vitrethane 650’s resistance to adverse damages remains critical to achieving the best value from the truck body.

Vitrethane 650 allows mine sites to function at peak productivity, avoiding higher levels of downtime associated with constantly repainting and maintaining machinery, or similarly removing machinery for repairs due to corrosion or damage at off-site locations.

Complementing A&I’s isocyanatefree polyurethanes is Vitrephos 560, an isocyanate-free epoxy primer.

Vitrephos 560 has high-quality application and drying properties in cold weather, wet-on-wet properties with ease of sanding, and effective film builds that have seen a significant reduction in the number of hours required to complete projects.

As a smooth-drying application, the enhanced topcoat achieves significant surface coverage, ensuring reductions in planned downtime are consistently achieved.

With Vitrephos 560 primer and Vitrethane 650 topcoat, A&I Coatings offers a complete isocyanate-free coating system that is versatile and can be used across most mining equipment and machinery applications.

By displaying the desired balance of mechanical properties, such as flexibility, impact resistance, surface hardness, toughness and adhesion, Vitrephos 560 and Vitrethane 650 exceed the service requirements for a specific application and withstand the adverse effects of corrosion and other damage.

Corrosion is a constant threat to equipment, plant and infrastructure across the resources sector.

Companies can be assured there is no risk of exposure to harmful chemicals for employees, and no need to compromise on quality.

Vitrethane 650 is available in high-gloss, semi-gloss and satin finishes, and in an unlimited colour range, including fleet, construction, agricultural and earthmoving machinery colours.

Users can expect the topcoat to function like any high-performing polyurethane, from chemical-, abrasion-, and adhesion-resistance to weathering performance and flexibility, all without endangering the health of workers while removing the requirement for ongoing maintenance.

“We saw there was a need in the market for a high-performing and extremely durable coating that could withstand harsh environments and, importantly, did not contain dangerous isocyanates and significantly reduced maintenance costs,” Chesterfield said.

SAFETOWORK.COM.AU 31 JAN—FEB 2023

Industry awards

Your winners for the 2022 Prospect Awards SAFETY WAS A KEY THEME AT THE AUSTRALIAN MINING PROSPECT AWARDS.

The 2022 awards were held in WA for the first time.

A

ustralia is an unofficial mining capital of the world and the people who work tirelessly to support it deserve to be recognised for their efforts.

And since 2004, the Australian Mining Prospect Awards have been the premier event to do just that.

The Prospect Awards have been the only national awards program to take a step back and appreciate what the mining industry is doing by rewarding those who are excelling and going above and beyond, recognising and rewarding innovation.

SAFETY ADVOCATE OF THE YEAR The winner of the Safety Advocate of the Year award has a very simple

motto: It’s okay not to be okay. It’s okay to get help.

Nigel Gould, a Rio Tinto plant operator, has been a fierce advocate for men’s mental health since his first days as a fly-in, fly-out (FIFO) worker.

He dedicates his time to different charities in order to help as many people as he can.

The Safety Advocate of the Year award recognises an individual who is committed to ensuring safety – either for an individual site or company, or for the mining industry as a whole.

“In mining, you’re in a cab for hours and then in your donga and it can be really lonely. Men are sometimes not the best at communicating and it can get bad fast,” Gould said. “So I just try

and get people to talk, and I’ve been fortunate to save a couple of lives just by talking to people.

“I’m no expert; all I do is listen and not judge. But sometimes that’s all someone needs.”

Gould has been an ambassador for Movember, a charity aimed at raising awareness for men’s mental and physical health, for over a decade.

“It’s not just men’s mental health that Movember focuses on but things like prostate and testicular cancer, too,” Gould said. “It helps men to be aware of themselves and get those muchneeded check-ups.”

In an effort to raise more awareness for Movember, Gould sat for a portrait as part of the esteemed Archibald

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Prize. The portrait captured Gould’s character, mining experience and mental health advocacy.

“The portrait is the whole story of my career involvement,” Gould said.

“You’ve got the Royal Flying Doctor Service, the Movember big mo, the big wad of money because it’s not all about the money, even though that’s at the forefront of a lot of people’s minds.

“There’s a lot of meaning in the portrait.”

Gould called being named a Prospect Awards winner “an absolute honour”.

“I’m very fortunate to be known around the mine sites as someone people can go to for help,” he said.

Category sponsored by Flexco.

EXCELLENCE IN MINE SAFETY, OH&S

This award recognises a mine, company or project that has developed or carried out a program that increased safety, removed risk, or cut worker issues on a project or mine.

Emerging health safety and hygiene consulting firm GCG took home this award for its Real-Time Monitoring (RTM) App. “The team and I at GCG Health Safety and Hygiene are extremely grateful for the amazing recognition and wonderful support from Vocus,” GCG operations manager Richard Crafter said.

The Real-Time Monitoring App is an advanced software solution developed to provide intelligent dust-exposure control management for smarter, faster dust exposure control decisions.

GCG has partnered with industry to refine and optimise the innovation to ensure benefits will be realised, with Hunter Valley Operations (HVO) being just one company that reported benefits from using the app.

“The RTM app allowed HVO to conduct a deeper analysis of potential

Nigel Gould (left) was a worthy Safety Advocate of the Year winner.

worker exposure to respirable dust when undertaking a specific task, allowing for task-specific dust controls to be implemented and resulting in less exposure for the workforce,” HVO said in a case study.

Category sponsored by Vocus.

INNOVATIVE MINING SOLUTION

Recognising a mine, company or project that has developed a unique mining solution, the Innovative Mining Solution award was presented to RattleJack Innovations for its SafetySpear.

The SafetySpear was invented in response to the ever-present danger of falling drill rods in underground mining operations. Drill assemblies are necessary to the process of underground mining but are often left abandoned in blast holes, creating significant risks to operators and equipment within the space above.

“The SafetySpear is a proactive approach to mine safety,” inventor of the SafetySpear Leigh Sutton said.

Sutton himself was almost injured by this hazard in 2014, setting in motion the conception of the SafetySpear.

“The SafetySpear will silently save someone’s life and they won’t even know it,” Sutton said. “They will go home safely to their family and that, my friends, is what we all want.”

Category sponsored by Austmine.

OUTSTANDING MINE PERFORMANCE

This category merges the Coal Mine of the Year and the Hard Rock Mine of the Year awards of past years into a single category.

This was Kestrel Coal’s first win of the evening. For close to four years, Kestrel has steadily improved its longwall mining operation efficiencies, from longwall move,to reaching first one million tonnes of coal in a new longwall block.

Kestrel believes its strong operational performance is built on confident and capable leaders and teams. To that end, the company’s UNLEASHED leadership program aims to strengthen operations by investing in the strength of its people.

“Through capable and confident leaders, we’re determined to deliver our compelling vision and solid strategy to become the mining industry’s employer of choice,” the company said in a statement.

Category sponsored by SEW Eurodrive.

DISCOVERY OF THE YEAR

The Discovery of the Year was one of five new or updated awards making its debut in 2022. It celebrates a significant discovery at either a greenfields or a brownfields site.

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Industry awards Trigg took home this award for its Lake Throssell greenfields discovery in WA. Trigg founder, managing director and chief executive officer Keren Paterson said the company was “incredibly honoured” to receive the award.

“We would like to acknowledge the Traditional Owners, the Ngaanyatjarra Lands People, on whose traditional lands this discovery was made and their role in this accomplishment, the technical and field crews who have worked tirelessly to make this discovery and the award sponsor Bonfiglioli,” Paterson said Category sponsored by Bonfiglioli.

EXCELLENCE IN ENVIRONMENTAL MANAGEMENT & SUSTAINABILITY

This award recognises a mine, company or project that has developed or carried out an innovative, environmentally focused program to protect, preserve and/or rehabilitate the natural environment and improve sustainability.

IGO took home this year’s award.

“We were recognised as being an industry leader for our Internal Carbon Price and Decarbonisation Fund, which is an innovative and environmentally focused initiative which

improves sustainability and accelerates decarbonisation,” the company said following the awards.

“This is an important step towards delivering on our commitment to be carbon-neutral across our direct operations by 2035.”

Category sponsored by Metso Outotec.

EXCELLENCE IN IIOT APPLICATION

The Excellence in IIoT (industrial internet of things) Application award seeks to recognise an outstanding implementation of IIoT that enhances mining and mineral processing operations.

And the Flexco Elevate by Flexco Australia was this year’s worthy winner.

This belt cleaning monitoring system allows mining operations to remotely gather critical data and perform real-time analysis to boost belt conveyor efficiency.

Flexco Elevate is a wireless platform that transfers data via cloud technology and provides continuous and automated collection and monitoring of data. This reduces the need for on-site inspections, including those that could compromise employee safety.

Category sponsored by ifm.

Consulting firm GCG took home the Excellence in Mine Safety, OH&S award.

INDIGENOUS AND COMMUNITY ENGAGEMENT AWARD

Recognising collaboration between Aboriginal-owned businesses and mining and minerals processing companies operating within Australia, this award was presented to Atlas Iron for its major mining contract with East West Pilbara (EWP).

The contract was the first of its kind to be awarded on traditional land and is unique in that it is not a provision of a particular narrow service or activity, but rather all-encompassing.

EWP managing director Troy Eaton said the contract was a watershed moment.

“This will be the first Indigenous business in the Pilbara to be awarded such a valuable contract to conduct these specific mining services on their own native title lands,” Eaton said.

“I know my grandfather and Nyamal man Ernest Mitchell would be so proud of what we have achieved together. He has always believed that mining could benefit his people and first started looking for commercial opportunities in the 1960s.”

Category sponsored by Schenck Process.

MINE PROJECT SUCCESS OF THE YEAR

Another new award, this recognises a significant engineering and/or contract mining project that has been undertaken on a mine site.

Roy Hill won for its Wet High Intensity Magnetic Separator WHIMS plant Expansion Project.

The pioneering of the WHIMS plant in December 2019 allowed capture of high-grade ultrafine iron ore units that would otherwise have been waste.

When the original WHIMS initially processed ore in December 2019, Roy Hill was the first Australian

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The gala evening was a celebration of the Australian resources sector.

iron ore company to use magnetic separation in a hematite mine at that size and scale, reducing waste and increasing production by approximately 4mtpa.

Category sponsored by Epiroc.

PROJECT LEAD OF THE YEAR

The making of great mines starts behind the scenes, and the Project Lead of the Year award seeks to recognise those individuals who work to lead site projects to a successful outcome.

The deserving winner for 2022 was Stacey Brown, general manager – projects at Atlas Iron.

Brown is responsible for a pipeline of new projects, including two new major mines, the Sanjiv Ridge and Miralga hematite iron ore mines, both of which celebrated first ore during the height of the COVID-19 pandemic.

Brown oversees all stages of project development at Atlas, from pre-feasibility to site construction, and draws on her extensive experience in strategic development, corporate

leadership and communications to navigate these projects.

Category sponsored by Altra Motion.

AUSTRALIAN MINE OF THE YEAR

The Australian Mine of the Year recognises a mine site that is not only exceptionally wellperforming, but has also reached its production goals, implemented commendable safety controls, environmental and sustainability programs, and/or has shown its capacity to innovate in order to drive the industry ahead.

The award is imparted to the winner of one of the other categories, and after already taking home the 2022 Outstanding Mine Performance Award, Kestrel Coal Resources was a worthy recipient.

Kestrel underground operations manager Daniel Proffitt hailed the company’s “special year”.

“With purposeful investment into our safety and culture, our values drive high performance and mateship. In 2022, we have upheld our commitment to developing our people and our frontline

leaders, who are at the core of our success,” Proffitt said.

Category sponsored by National Group.

LIFETIME ACHIEVEMENT AWARD

Recognising an individual who has contributed to the Australian mining and mineral processing industries throughout their life, this is the most prestigious individual recognition award of the night.

The 2022 award was presented posthumously to Ron Sayers, who died last year. Sayers founded mining services company Ausdrill in 1987, growing his business into a billiondollar ASX200 global mining services company, now the Perenti Group.

Accepting the award, nephew Mark Swiderski said Sayers was passionate about his employees and fostering an outstanding workplace culture.

“Ron perfected the art of the deal, applying principles in work as he did in life,” he said. “He respected everyone, he acknowledged others who were experts in their respective fields.”

Category sponsored by Liebherr.

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Respiratory safety

It is estimated that hundreds of thousands of workers are exposed to silica dust each year.

Work hard and breathe easy

THE PROTECTION OF ON-SITE WORKERS IS IN HONEYWELL’S DNA, AND THE COMPANY HAS CREATED COMPREHENSIVE SOLUTIONS TO SAFEGUARD THE LIVES OF PEOPLE IN THE MINING AND CONSTRUCTION INDUSTRIES.

S

ilicosis has been flagged as a problem in the Australian mining, manufacturing and construction industry for some time, yet the dust disease remains highly prevalent today.

It is estimated that hundreds of thousands Australian workers are exposed to silica dust and black lung disease each year, with many developing lifelong issues as a result.

Recent legislative changes are aimed at tightening occupational exposure limits (OELs) or workplace exposure standards (WES) for coal and silica dust in mining operations.

As the regulatory environment has changed and new safety requirements mandated, Honeywell has continued to innovate to ensure its solutions meet the changing needs of mines and constructions sites across Australia.

The legislative changes regarding silica, adopted from July 1 2020, include most states accepting Safe Work Australia’s recommendation to halve the WES for respirable crystalline

silica from an eight-hour time-weighted average airborne concentration of 0.1 milligrams per cubic metre (mg/m³) to 0.05 mg/m³. Tasmania remains an outlier, observing standards set in 2018.

And for coal dust, since October 1 2022 all coal mines across the country are regulated by a new dust respirable exposure standard of 1.5mg/m³, a reduction from the previous standard of 2.5mg/m³. Queensland moved early and adopted these standards in 2021.

To achieve consistent site-wide dust control and to stay within mandated OELs most effectively, mines must address each dust-generation point separately with targeted solutions.

This includes every stage of the mining process from pit to port.

Many mines focus most dust control efforts on haul road networks; however, it is critical for mines to tackle dust issues in relation to production and processing plants, as well as activities

Honeywell’s powered air-purifying respirators support most industry requirements and are designed for comfort, safety and easy operation.

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where workers are directly exposed to dust in more confined spaces, such as underground mining and drilling, or spaces within processing plants.

In general, work health and safety (WHS) regulations involve managing risks to everyone in the workplace.

Creating a safe work environment is a legal requirement, critical to the long-term success of mining and construction. It can help with staff retention and improve productivity, reduce injury and illness in the workplace and reduce the costs of injury and workers’ compensation.

Under Australian WHS laws, mines must ensure the health and safety of workers and not put the health and safety of other people at risk.

People working in the mining and construction industries have WHS obligations and they must take care of their own health and safety, take care not to do anything that could hurt others, follow WHS instructions, and follow the workplace’s WHS policies and procedures.

Across the mining, manufacturing and construction industries, personal protective equipment (PPE) is no less important than any other safety measure contained within WHS regulations. The biggest challenge with PPE is that it relies on worker behaviour to be effective 100 per cent of the time.

When respirators are required in a workplace, the need to develop a Respiratory Protection Program (RPP), as per the AS/NZS 1715 standard is critical; however, this can be challenging as workplaces aren’t often aware what an RPP entails.

The use of respirators means a systematic approach to provide a high level of confidence and ensure workers are going to be protected, especially from silica dust.

There are three main areas that must be addressed with RPP: the type of

filter; the adoption of the respirator (as it needs to be worn 100 per cent of the time when protection is required); and that it must fit the wearer to create an adequate seal.

Workers also need to consider other factors that fall within these three main categories, such as whether the respirator is adequate and suitable for the work that is being completed.

Selecting respiratory equipment goes well beyond the filter. Facial structure, facial hair, the time in which a task is performed, environmental conditions, physiological impacts and communication requirements are essential to the selection process of a respirator.

Honeywell offers a range of reusable respirator solutions, half-face and fullface masks, and 7700 Series P2/P3 asbestos silica kits.

Honeywell’s new product offering is the powered air-purifying respirator with a selection of hoods that supports most industry requirements.

These are designed for superior comfort, safety and easy operation so users can work hard and breathe easy.

Silica dust can be found on almost all mine sites, particularly where workers are grinding, sawing, and cutting materials like

concrete, stone, brick, mortar, and sand.

Without the proper respiratory protection, workers may not see or feel the effects in the short term, but could end up with serious health issues later in life. That’s why WHS mandates that employers limit workers’ exposure to respirable crystalline silica and provide the appropriate filtering respirator.

It’s also why respirator solutions such as those provided by Honeywell are so important.

Comfort plays a large part in respiratory protection compliance and if respirators aren’t comfortable workers won’t wear them correctly – or even at all.

Honeywell’s respirators more than fit that bill. The company’s safety solutions help to effectively mitigate the effects of silica dust, lead to productivity and efficiency gains, and do not get in the way.

Above all, they don’t stop working until the last person safely clocks out and heads home.

Visit the Honeywell website for further information.

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Honeywell offers a range of reusable respirator solutions.

Fire suppression

More than water

JSG INDUSTRIAL SYSTEMS’ ADVANCED FIRE SUPPRESSION TECHNOLOGY PROVIDES THE MOST SUITABLE SOLUTION WHEN WATER ALONE IS INEFFECTIVE.

F

ires can happen at any kind of workplace. And with so many chemicals and moving parts in operation at any given time, a mine site is certainly no exception.

Fortunately, JSG Industrial Systems is in the business of providing technologically advanced, fully monitored and highly reliable fire suppression solutions to a wide cross-section of industry customers, including – but not limited to – mining.

With decades of experience, JSG understands the implications of ineffective fire suppression technology, especially when it is required to perform in high-risk areas.

JSG distributes the next generation in fire suppression technology with the Muster range of products, featuring several new and upgraded component releases, offering straightforward design with a quick-to-connect wiring system.

“The Muster foam system is a preengineered foam-water spray system suitable for many mobile applications, such as heavy earthmoving equipment within the mining sector,” JSG’s national product sales manager – fire Dale Sharpe told Safe to Work. “(It’s also suitable for) combine harvesters in the agriculture sector, various machinery in the forestry industry, as well as on fixed applications such as hydraulic power units.”

The Muster foam system is a highly effective solution for the protection of assets where liquid hydrocarbon fuels pose a high

fire risk and, under emergency conditions, when water alone is ineffective or potentially dangerous.

The system is available with multiple foam types to suit a range of applications, effective from -40°C to +60°C. Muster offers an environmentally responsible fluorinefree foam (F3), helping to minimise environmental impacts.

With seven different cylinders sized from 15L capacity to 110L capacity, which can be fitted individually or in multiples, the system can be configured to a wide range of equipment.

“You can have one small cylinder, or one large cylinder, up to potentially eight large cylinders depending on the size of the machine, filled with foam and water, pressurised with nitrogen,” Sharpe said.

“The Muster system features a ring main that can be manufactured out of fire-resistant hose or stainless-steel tubing, linked to nozzles that direct the agent to the risk areas – a source of fuel or of heat.

“The system is specifically designed for Class B fire risk, including diesel, petrol, oils, greases and other flammable liquids.

“Foam works exceptionally well on Class B fires. For instance, if a hydraulic oil line ruptures in an engine bay and is spraying fluids into a hot turbo, the Muster system rapidly suppresses the fire with an effective fluorine-free foam and water combination.

“It will also cover the remaining leaking oil, ensuring further ignition doesn’t occur.”

JSG distributes the next generation in fire suppression technology.

The foam in the solution is designed to create a blanket, effectively sealing the vapours and preventing ignition, while the water in the solution provides cooling to heated components.

Foams are supplied in concentrates that are appropriately proportioned with water. They are then aspirated with nitrogen gas to produce foam bubbles and discharged through a pre-engineered fire suppression system specifically designed to protect areas of risk.

The in-built accuracy of the Muster system is controlled using state-ofthe-art intelligent pressure sensors.

The Muster system is available in two fire-sensing modes: MusterWire Linear Heat Detection (LHD) wire sensing, and Loss of Pressure (LOP) sensing.

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Both modes are always monitored, allowing the operator to view the overall integrity of the system, ensuring it is at the correct pressure with all sensors active and that the system is ready to actuate any time a fire is detected.

At the heart of every Muster system is a sophisticated alarm panel that monitors the integrity of the fire suppression system and automatically controls its activation.

“The Muster system features an alarm panel which controls the system, interfacing with the machine and allowing it to shut down the machine’s engine in the event of a fire, audibly alarming to notify the operator to initiate emergency procedures and disembark to safety,” Sharpe said. “There is also automatic detection; if there’s a fire and the machine is unmanned it will activate the fire system.

“Most of the fire suppression systems installed by JSG feature automatic detection, so if there’s a fire in an identified risk area the alarm panel is notified, instantly activating the system.

“A diagnostic module can also be utilised by service technicians,

The Muster foam system is a solution for when water alone is ineffective or potentially dangerous.

enabling the identification of faults on the alarm panel, as well as access to the operating history.”

The Muster system is configured with stainless steel components, including the valve, cylinder, and fittings, ensuring its performance durability under extreme temperatures and weather conditions.

“All Muster fire suppression system key componentry is manufactured from stainless steel, which ensures longevity, critically important within corrosive environmental conditions, either in surface or underground mining operations,” Sharpe said.

A Muster foam system can be used as a standalone system or in conjunction with a Muster Impulse Powder System (IPS) or with a Muster Solid Aerosol Generator System (SAG), configured as a dual agent system.

The Muster fire suppression system falls under AS 5062:2016, the fire protection for mobile and transportable equipment standard, dictating that the unit must be serviced at six- and 12-month intervals.

The Muster range offers straightforward design with a quick-to-connect wiring system.

“The six-monthly service is a simple inspection of the system, and at 12 months you replace the fluid solution, check the operational condition before refilling and recharging the system and completing a range of additional checks,” Sharpe said.

Heavy vehicles, mobile plant, agricultural machinery, stationary equipment, and other assets represent a substantial investment for any business. Strategies to reduce risk must include the often-heavy demands placed on performance, and consideration should be given to damage or potential personal injury because of a fire incident.

The costs of asset replacement and lost production can be significant, but pale in comparison to potential loss of life.

“The Muster fire suppression system is a reliable, robust and environmentally responsible system,” Sharpe said. “It’s also an essential part of an inclusive risk-management plan that is designed to save lives and protect equipment.”

SAFETOWORK.COM.AU 39 JAN—FEB 2023

Safety regulation

Regulations around the country Working on a mine site comes with a number of inherent risks.

AUSTRALIA’S SUCCESS IN MINING IS UNDERPINNED BY LOW RATES OF INJURY AND LOSS OF LIFE, DUE IN LARGE PART TO THE EFFORTS OF THE VARIOUS STATE AND TERRITORY INDUSTRY REGULATORS.

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he Australian mining industry has made major improvements in health and safety over the last decade, significantly reducing the incidence of fatalities and serious injuries.

The sector’s core value is its commitment to the safety, health and psychological wellbeing of its workforce, where everyone who goes to work returns home safe and healthy. And industry regulation is a key component of this obligation.

But there is always room for improvement. As they say, one workplace fatality is one too many.

While the industry’s fatality rate has decreased, it remains the third highest of any industry in Australia.

Mining comes with any number of inherent risks, including body stress, manual handling and musculoskeletal disorders, slips trips and falls, and being hit by moving objects or machinery, as well as working with high-risk plant in instances where it has not been properly maintained.

And while the industry works to eliminate fatalities, injuries and occupational illnesses, with a strong focus on building and sustaining respectful workplaces, state and territory regulators are responsible for enforcing integrated and holistic frameworks designed to ensure stakeholders understand and comply with all of their safety obligations.

The mining industry recognises that continuous effort is needed in areas of leadership, people, culture, behaviour and systems, working collaboratively with all stakeholders and supported by risk-based regulation.

As with integrated safety and health practices across varied operations, the industry seeks an integrated approach from governments to support a growing, diverse and mobile workforce. This integrated approach should not detract from the practical task of identifying hazards, managing, and controlling risks, and the continuous improvement of safety and health outcomes.

The Australian Government does not regulate work health and safety

(WHS) in the mining industry – that is the responsibility of the states and territories.

NEW SOUTH WALES

The Work Health and Safety (Mine and Petroleum Sites) Act 2013 and Health and Safety (Mines and Petroleum Sites) Regulation 2014 are the two frameworks that regulate WHS requirements for NSW mining.

The NSW Resources Regulator plays a varied role, including receiving and considering complaints, alleged breaches of the Mining Act and safety incident notifications, conducting inspections and investigations and taking enforcement action such as issuing prohibition, among others.

VICTORIA

Chapter 5.3 of the Occupational Health and Safety Regulations 2017 (OHS Regulations) regulates WHS requirements for Victoria.

These regulations build on the Occupational Health and Safety Act

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2004 (OHS Act) and set out how to fulfil duties and obligations, and particular processes that support the OHS Act. The OHS Regulations came into effect on June 18 2017 and replaced the (old) OHS Regulations 2007.

WorkSafe Victoria is the state’s workplace health and safety regulator.

QUEENSLAND

As one of the most resource-rich states, there are four acts and regulations that regulate Queensland’s WHS requirements: • Mining and Quarrying Safety and Health Act 1999 • Mining and Quarrying Safety and Health Regulation 2017 • Coal Mining Safety and Health Act 1999 • Coal Mining Safety and Health Regulation 2017 Other laws may impact on safety and health for specific activities, including the Explosives Act 1999 and the Radiation Safety Act 1999.

The Queensland Department of Resources is responsible for the regulation of the state’s mining health and safety.

WESTERN AUSTRALIA

Like Queensland, WA is another of the most resource-rich states in Australia.

However, only one act and one regulation cover the WHS requirements for the state: Mine Safety and Inspection Act 1994 and Mines Safety and Inspection Regulations 1995.

The Department of Mines, Industry, Regulation and Safety is responsible for the regulation of the state’s mining sector after the merging of the Department of Commerce and Department of Mines and Petroleum.

SOUTH AUSTRALIA

Chapter 10 of the Work Health and Safety Regulations 2021 (SA) regulates the WHS requirements for mining in SA. SafeWork SA is responsible for advice and education on WHS, providing licences and registration for workers and plant, investigating workplace incidents and enforcing WHS laws in the state.

TASMANIA

The Mines Work Health and Safety (Supplementary Requirements) Act 2012 and Mines Work Health and Safety (Supplementary Requirements)

Different states and territories are subject their own rules and regulations.

Regulations 2012 set the WHS requirements for Tasmania.

Amendments to the Work Health and Safety Regulations 2012 came into effect on December 22 2021 and included updating reference to the Workplace Exposure Standard for Airborne Contaminants to give effect to reduced limits for lead (inorganic dusts and fumes) and silica (crystalline) dust and inserting a new regulation (regulation 216A) which deals with safe use of quad bikes, among other things.

WorkSafe Tasmania is the body responsible for the regulation of the state’s mining health and safety.

AUSTRALIAN CAPITAL TERRITORY

One act and one regulation set the WHS requirements for the ACT: Mines Health and Safety Act 2011 and Work Health and Safety Regulation 2011.

NORTHERN TERRITORY

The Work Health and Safety (National Uniform Legislation) Act and chapter 10 (Mines) of the Work Health and Safety (National Uniform Legislation) Regulations set the WHS requirements for the NT. The legislation covers five areas: • Workplace health and safety • Works rehabilitation and compensation • Transport, storage and use of dangerous goods • Electrical safety • Transport and storage of radioactive ores and concentrates NT WorkSafe is a division under the Department of Attorney-General and Justice responsible for assisting businesses and workers understand their obligations under work health and safety.

The acts and regulation, and the regulatory bodies, that are at work in each state and territory help Australia to reduce the rates of fatalities and serious injuries in the mining industry.

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Gold

Gold mining is reinforced by critical maintenance WESTGOLD’S SOPHISTICATED APPROACH TO MAINTENANCE IS BASED ON DETAILED PLANNING AND SCHEDULING, ADVANCED TECHNOLOGY AND HIGHLY SKILLED TEAMS OF PROFESSIONALS.

T

he need to undertake regular and effective machinery and equipment maintenance is vitally important for gold mining operations, specifically in relation to the health, safety and wellbeing of employees.

Gold miners operate complex equipment in often-harsh surface and underground environments, ensuring mine maintenance is no easy task.

Westgold’s regional operations maintenance manager Bryan West notes that protecting the safety of the machinery and equipment operators, and those working within an underground gold mining environment, is critical.

“Ensuring the safety of the operators and all the other personnel who work underground is the most essential part of what we do,” West told Safe to Work.

The requirement for properly maintained and reliable mining tools is key to achieving uninterrupted and sustainable safety outcomes.

“Well-maintained equipment allows us to operate our assets efficiently and predictably by limiting unplanned and costly downtime, and boosting productivity by keeping the wheels turning,” West said.

“It allows us to predict and control costs, and to reach the required operational targets required to remain profitable.”

West is responsible for the maintenance of Westgold’s mining fleet and auxiliary assets, ensuring compliance for classified plant and equipment. He acts as a link between corporate and site-based personnel, facilitating continuous improvement.

Westgold has a strong focus on the health of its operators.

He also helps to ensure company processes and operating procedures are followed, while supporting and engaging the company’s personnel by working closely with recruitment and HR teams.

Westgold is a dynamic and responsible explorer and developer of gold mines, operating in the prolific goldfields of Western Australia.

The company typifies Australia’s world-leading mining technology, ingenuity and pioneering attitude. It has two main pillars: gold operations in Murchison and Bryah Basin in WA; and a specialised underground mining services arm, Westgold Mining Services.

With a workforce of more than 1000 people, Westgold is the dominant explorer, developer, operator and gold mining company in the Murchison region.

With over 1300 square kilometres of tenure across the Murchison and Bryah Basin, the company operates four underground mines and three processing plants with an installed processing capacity of around four million tonnes per annum.

Westgold is the owner–operator of all its underground and open-pit mines. This vertical integration provides greater cost control and operating flexibility across the company’s assets.

Westgold operates on a ‘hub and spoke’ model. Its Murchison mines are able to feed ore to the Meekatharra and Tuckabianna processing hubs, with the Bryah Basin mines sending ore to the Fortnum hub.

SAFETOWORK.COM.AU 42 JAN—FEB 2023

“Ensuring the safety of the operators and all the other personnel who work underground is the most essential part of what we do.”

Gold miners operate complex equipment in often-harsh environments.

All of Westgold’s mining operations rely on specific types of machinery and equipment maintenance. The company undertakes its scheduled maintenance via utilisation or calendarbased maintenance.

“The majority of Westgold’s frontline equipment, haul trucks, loaders and drilling equipment is serviced under a utilisation regime based on intervals of 250 machine hours,” West said.

“Calendar-based service intervals require inspections to be conducted either on a weekly, fortnightly, monthly and three-monthly basis.”

Westgold has many equipment programs that support mining activity, including the rebuild and replacement of machines and components.

“Additionally, there is classified plant servicing, which is conducted on three-, six- and 12-month intervals dependent on the regulations that apply to the specific regime,” West said.

Westgold has many equipment programs that support mining activity, including the rebuild and replacement of machines and components.

The company monitors the life expectancy of machinery and equipment according to economical and productivity expectations.

It also engages in continuous improvement projects, including the acquisition of Caterpillar’s R2900 XE, a new diesel-electric underground loader that is currently in service at the miner’s mid-west operations.

The diesel-electric combination of the R2900 XE offers more than a 31 per cent improvement in fuel efficiency, alongside reduced maintenance costs and greater productivity compared to earlier models.

Westgold believes this type of machine innovation is a key driver for enhancing productivity and profitability.

The company also undertakes predictive and preventive maintenance using the maintenance management system, Pronto. This system allows for the capture and storage relevant data relating to individual machines and groups of assets.

Westgold utilises reporting tools, such as Qlik Sense, that provide information relating to machine availability, utilisation, downtime and repair trends, and cost analysis, using this information to make improvements to the overall reliability of its assets by targeting potential problem areas.

Westgold has been improving its workshop facilities and tooling over the last couple of years, which has given the company’s personnel the ability to perform the right level of maintenance.

Additionally, Westgold is deeply engaged in providing the most appropriate types of training.

“For employees without a trade certificate, we have apprenticeship

training programs in place for heavyduty fitters and auto electricians, while also providing opportunities for trade upgrade training,” West said.

“We are in the process of setting up a dedicated training facility at our Great Fingal operation in the Cue region, where our apprentices can spend time with trained and experienced tradespeople to help reinforce the knowledge they have learned through TAFE programs and on-the-job training “They will get to work on components and systems that they might not get the opportunity to work on often at site in a non-productionbased environment, and on operational equipment and components.

“For those that have already completed an apprenticeship, we offer various tailored training with our OEM (original equipment manufacturer) partners and other outside sources to help upskill and engage our teams.”

Westgold is also a proud member of the Gold Industry Group, a memberbased, not-for-profit association that represents gold producers, explorers, prospectors, fabricators and service providers. The organisations champions long-term initiatives that grow an understanding of the gold sector’s value to the economy and community.

The Gold Industry Group, along with members such as Westgold, is working to build a strong, sustainable, connected and safe gold industry, exemplified in its commitment to the role of maintenance.

SAFETOWORK.COM.AU 43 JAN—FEB 2023

Human rights

Miners tackle modern slavery

It is estimated that 50 million people were living in modern slavery in 2021.

WHEN FORTESCUE PUBLISHED ITS MODERN SLAVERY STATEMENT IN DECEMBER 2022, IT BECAME THE LATEST MINING COMPANY TO REAFFIRM ITS COMMITMENT TO RESPECTING FUNDAMENTAL HUMAN RIGHTS.

“I

t isn’t a thing of the past.”

That is Fortescue executive chairman Andrew Forrest in a statement addressing modern slavery in the global resources industry.

“Modern slavery is one of the biggest and most complex human rights issues facing the world,” Forrest said.

“It is occurring in almost every country, with women and children continuing to be the most vulnerable.”

WHAT IS MODERN SLAVERY?

Modern slavery refers to a range of human rights violations. The term is used to describe situations where coercion, threats or deception are used to exploit people and deprive them of their freedom.

It includes trafficking in persons, slavery, servitude, forced marriage, forced labour, debt bondage, the worst forms of child labour, and deceptive recruiting for labour or services.

In the context of the modern resources sector, the push into new areas of mining may be inadvertently opening the doors to insidious labour practices around the world.

“The need to decarbonise means that the global energy mix is rapidly shifting,” KPMG purpose officer and partner in

charge Richard Boele said. “This shift is creating increasing crossover between the resources and energy sectors in both their operations and supply chains.

“It’s in this context that companies must challenge their thinking on where they’ll find risk to people. Transition is creating new and emerging human rights and social risks that we have to identify and understand.”

According to the International Labour Organisation, latest estimations show that forced labour and forced marriage have increased significantly in the last five years.

The latest Global Estimates of Modern Slavery show 50 million people were living in modern slavery in 2021, of whom 28 million were in forced labour and 22 million trapped in forced marriage.

MAJOR MINERS’ STATEMENTS Fortescue publishes a statement under Australia’s Modern Slavery Act 2018 each year, with the 2022 edition marking the fifth such publication.

The latest statement highlighted key actions taken during the 2021–22 financial year to combat modern slavery:

• C ompletion of a salient human rights risk assessment to identify areas with greatest potential to impact the human rights of people across Fortescue’s value chain • L aunch of a modern slavery procurement procedure to provide a framework for supplier screening • I ntroduction of a mandatory online human rights training module for all employees In the same way Boele highlighted decarbonisation as a risk area, Fortescue identified its global expansion into green energy as a potential risk, explaining that it could cause or contribute to modern slavery in countries with a high prevalence of the practice.

The report gave the example of a situation in which “employees or contractors were engaged in exploitative situations, or if our workforce, in their personal capacity, engaged in exploitation of the local community”.

“These risks are greater in countries that have a higher prevalence of modern slavery,” the report stated.

“In addition to in-country risk assessments, we are working to ensure human rights and modern slavery due diligence measures are implemented across the Fortescue Group.”

SAFETOWORK.COM.AU 44 JAN—FEB 2023

Fortescue is not the only miner to tackle the issue.

Glencore, IGO and AngloGold Ashanti have also released statements reaffirming their commitments to addressing modern slavery.

“Glencore is committed to preventing the occurrence of modern slavery and human trafficking in our operations and supply chains,” the company’s statement read.

Glencore’s report detailed the progress it made in 2021, including implementing a group social performance standard that requires industrial assets to develop a system to receive, investigate, respond to and provide remedy for social performance issues.

In AngloGold’s statement, the company said it recognised that there are risks it needs to monitor closely,

“particularly in respect of some of our developing-world operations, such as risks associated with local supply chains”.

“Like all major employers in economically underdeveloped regions, our operations are expected to prioritise local procurement to facilitate economic development,” the statement read.

“We recognise the requirement for methodical human rights due diligence in environments where these risks are pronounced.”

In IGO’s 2021 statement, the company said it would adopt a continuous review-and-improvement approach to its management of modern slavery risks, extending to how the company evaluates the effectiveness of its actions.

The company said it aimed to achieve several actions in FY22:

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• Formalise the processes followed to perform modern slavery due diligence • Review and refine the initial risk assessment data assessment sources • Continue to build the performance monitoring and evaluation system • Develop a supplier code of conduct • Deliver targeted, risk-based training for departments within the business Modern slavery occurs in almost every country in the world. It cuts across ethnic, cultural and religious lines, with migrant workers being more than three times as likely to be in forced labour than non-migrant adult workers.

With effective policies and regulation, it is hoped that major players in the global resources industry can play a big role in helping to eradicate modern slavery.

Maintenance

Predict and prevent impending equipment failures

Predicting and scheduling maintenance is vital in limiting downtime.

DINGO PROVIDES PREDICTIVE MAINTENANCE SOFTWARE SOLUTIONS FOR ASSET-INTENSIVE INDUSTRIES, HELPING TO REDUCE MAJOR COMPONENT FAILURES, AND IMPROVE ASSET RELIABILITY AND SAFETY.

T

he profitability of mining operations is significantly affected by the availability and health of essential physical assets.

Dingo is a specialist in predictive maintenance, and its Trakka software provides actionable intelligence to asset-intensive industries such as mining and defence.

“Over many decades, Dingo has been servicing clients in the heavy mobile equipment space, across industries, providing unique and tailored advice to assist with the transition from preventive or older maintenance regimes to predictive maintenance strategies,” Dingo’s senior product manager Tom Mulherin told Safe to Work.

“Our core software product, Trakka, is a desktop application which monitors condition intelligence, essentially reviewing

and analysing condition data from assets.”

The software captures health information from mining machinery and uses a proprietary analytics platform to assess equipment condition.

Most recently, Dingo has released intelligence, an automatic reporting app that provides high-level and quick insights into Trakka data. The app can also reveal data hygiene issues and cross-examine asset health program results.

“We also provide sophisticated mobile solutions to assist with the collection of inspection data for the provision of insights and analysis,” Mulherin said.

Dingo’s Trakka Asset Health Manager (TAHM) mobile app enables asset-intensive operations to access, understand and act on the condition of its equipment – anywhere and

at any time. This app is part of a comprehensive suite of tools designed to help a team manage and maintain equipment health.

TAHM consists of two distinct but equally important functions: insights and inspect.

Insights enables users to see equipment health, recommend actions and track progress through to resolution.

Inspect allows technicians to easily perform equipment inspections and condition-reporting from the field using a mobile device.

If problems are found, the system, which seamlessly integrates with a mining operation’s existing workflow, alerts maintenance teams and recommends corrective actions.

“Our software remains both OEM (original equipment manufacturer) and hardware-agnostic, so we’re happy for miners to have mixed

SAFETOWORK.COM.AU 46 JAN—FEB 2023

fleets and choose any data provider and we’ll ingest that diagnostic information,” Mulherin said.

“Likewise, on the backend we seamlessly integrate with ERPs (enterprise resource planning) where maintenance work order management is completed.

“The software generates actions based on equipment reviews or analysis of the data. These actions transfer into the work order system, the maintenance work is completed, and unique to Trakka actions are tracked through to completion.

“Rather than assume the work order has been completed, and therefore the machine is now healthy, our software verifies whether the completed actions were in fact the right actions, returning the asset to a normal condition. And if not, the work order loop is restarted, ultimately leading to increased availability and fewer unplanned failures.”

Predictive maintenance is based on the actual operating condition of equipment, rather than predetermined factors.

Recent studies have suggested this form of maintenance can generate significant reductions in costs and downtime due to equipment breakdown.

“We provide analytic tools that capture a wide range of equipment condition data, including oil or fluid samples, vibration, thermography and ultrasonics,” Mulherin said.

“Additionally, we undertake simple tasks such as digitising the maintenance paper trail, allowing maintenance teams to use a digital inspection checklist and collate all that important data into one easily accessible platform.”

It’s not uncommon for mines to have data silos, where their condition-monitoring data is generated by different systems

and reviewed by different people.

But these types of fragmented systems and data storage make it easy to miss critical pieces of the puzzle, which can result in issues snowballing into larger and more expensive problems.

“Our experience tells us that the more mature mines believe they have to collect all of the data they can, while smaller mines believe they don’t have the ability to collect data due to the perceived expense,” Mulherin said.

“However, it’s really about collecting the right type of data that can have an immediate impact upon equipment health.”

The solution is to bring all data into a centralised predictive maintenance system like Trakka, which fits seamlessly within operations. Dingo’s early-warning software gives maintenance teams the actionable knowledge required to promptly rectify impending issues, resulting in increased availability and fewer unplanned failures.

Many mines assume they need to throw out their existing processes to implement predictive maintenance, but that’s not the case with Dingo.

Trakka will support existing maintenance processes, thus avoiding the need to make significant changes to the way work is done.

If a mine is utilising an ERP system, for example, Trakka can be a powerful complement by directly integrating with it or by operating in parallel.

In addition, Trakka provides quantifiable data on breakdown avoidance savings, including parts and downtime, along with savings associated with component life extension. Users can immediately understand how equipment health has improved over time and the financial significance of each save.

Dingo senior product manager Tom Mulherin.

“The power of Trakka is that our clients can transfer all their condition data into one place,” Mulherin said.

“When you have the complete picture of an asset’s condition, it’s much easier to make an informed decision in relation to its status” The transition to a predictive maintenance regime can be facilitated by Dingo experts, offering implementation and training sessions remotely or on-site to guide employees through the process.

Dingo is a proud member of Austmine and fully embraces the collaborative and supportive environment fostered by the organisation across the mining, equipment, technology, and services (METS) sector.

Dingo specialises in providing optimised planning, minimising downtime and repair costs, creating safer workplaces, maximising asset health, and delivering superior financial results.

“With predictive maintenance, Dingo’s typical mining customers routinely achieve payback in six months or less, and a threeto-one return on investment,” Mulherin said.

SAFETOWORK.COM.AU 47 JAN—FEB 2023

Workplace safety

It’s important for efforts to be made to create safer workplaces in the mining industry.

Majors come together to create safer workplaces RIO TINTO, BHP AND FORTESCUE HAVE LAUNCHED A PILOT PROGRAM AIMED AT HELPING TO ELIMINATE DISRESPECTFUL BEHAVIOURS IN THE RESOURCES INDUSTRY.

T

here is little doubt working in the mining industry can have its challenges.

Harsh conditions, time away from family, long hours, labour-intensive work, physical isolation. There’s a reason people in the mining industry are on average among the most well paid in Australia.

But when you add something as insidious as sexual harassment – or bullying and racism – into that equation, the situation will often become untenable and a higher-than-average salary is not going to be enough to keep someone in the industry.

It would be disingenuous to suggest any workplace is 100 per cent immune to these types of disrespectful behaviours, but recent inquiries and studies have shown people working in the mining industry, especially women, are at risk of being on the receiving end of poor conduct.

“It is no secret that mining is a tough industry, exacerbated by the practice of ‘fly-in, fly-out’ (FIFO) common across the industry,” researchers wrote in the Western Australian Government’s 2022 report, Enough is enough: Sexual harassment against women in the FIFO mining industry.

“People have for decades been required to work and live in remote places, where the difference between work and recreation is blurred, and where companies have an unusually high level of control over what people do.”

The WA Government was compelled to initiate the report following a series of reports of sexual assault and harassment in FIFO workplaces, “when the prevalence of sexual harassment across industries and sectors was becoming increasingly apparent”.

The final report made for some confronting reading.

“The shocking conclusion we had to draw was that sexual harassment

has long been and continues to be prevalent across the industry,” the researchers wrote.

This inquiry, and many others like it, may have been the shock the industry needed to make changes.

The results of the recent fifth national survey on sexual harassment in Australian workplaces reflect the extensive efforts the mining industry is taking to address the issue.

According to the survey, reported rates of sexual harassment in the Australian mining industry have decreased from 40 per cent to 32 per cent since 2018, below the national incidence rate of 33 per cent.

The survey showed that 62 per cent of women in mining experienced sexual harassment in the past five years (74 per cent in the 2018 survey) and 25 per cent of men (32 per cent in 2018) in the industry.

A pilot program that was recently launched by Rio Tinto, BHP and

SAFETOWORK.COM.AU 48 JAN—FEB 2023

“The launch of this pilot is a key milestone in our broader commitment to create a workplace culture that is safe, respectful and inclusive.”

Fortescue is another example of efforts towards change.

The Building Safe and Respectful Workplaces program comes after the major miners formed a partnership in October last year as part of their response to reports of sexual harassment in the mining industry.

The three companies have worked together with leading experts to design and develop the industry-first program aimed at educating new entrants to the sector.

“The launch of this pilot is a key milestone in our broader commitment to create a workplace culture that is safe, respectful and inclusive,” Rio Tinto iron ore chief executive, Simon Trott said.

“Building awareness through education on how we can create safer work environments through the prevention and elimination of sexual harassment, bullying and racism is vital to ensuring those joining our industry feel safe.

“We’re proud to be collaborating with experts in this field, in partnership with industry leaders, and we look forward to the findings from the pilot and the opportunity to share with broader industry for the benefit of all Australians.”

The evidence-based program will educate participants about the impact of sexual harassment, bullying and racism, including how to recognise and report these behaviours.

“Programs such as this help educate the next generation of workers to ensure our workplaces are safe, respectful

and inclusive,” BHP WA Iron Ore asset president Brandon Craig said.

“While we know there is more to do, this pilot is part of our redoubled efforts to eliminate sexual harassment and is in addition to a range of other measures, including improved security at accommodation villages, additional public disclosures, specialised resources and company-wide training.

“We’re proud to be working with leading industry partners to deliver this important program as we work together to eliminate disrespectful behaviours from our industry.”

The Building Safe and Respectful Workplaces pilot program, managed by the Australian Minerals and Energy Skills Alliance (AUSMESA), will be completed by 30 volunteers who are currently undertaking apprenticeships or traineeships with the three companies.

The results of the pilot will be evaluated and feedback from the participants will be used to finalise the learning program. It is intended the program will be delivered from early 2023.

As part of the ongoing commitment to educate about respectful behaviour, Rio Tinto, BHP and Fortescue will engage across industry and education providers on how to broaden the reach of the program.

“At Fortescue, safety is our first priority and we have zero tolerance for inappropriate behaviour,” Fortescue chief operating officer iron ore Dino Otranto said.

“We remain firmly committed to ensuring that Fortescue has safe and inclusive workplaces, and that the mining industry as a whole is a safe and welcoming place for everyone who works within it.

“We’re pleased to be working with our industry peers towards the common goal of ensuring that sexual harassment, bullying and other inappropriate behaviours do not occur in the mining industry.”

It is anticipated the training course will be made available to other industries in the future through a range of education pathways.

The nature of the mining industry can be made more difficult by fly-in, fly-out work.

SAFETOWORK.COM.AU 49 JAN—FEB 2023

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