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TRANSPORT SAFETY BUSINESS SWEDEN – THE SWEDISH TRADE & INVEST COUNCIL
26 September 2013
UNCLASSIFIED
RP 35 - MANAGING RISK OF
EQUIPMENT – PLANT –
PERSONNEL INTERACTIONS IN
MINING OPERATIONS
Gareth Williams
Head of Safety, Anglo American Plc
UNCLASSIFIED
OUTLINE
• Overview of Anglo American
• Challenges in managing transportation risk
• RP 35 Process
• RP 35 Stakeholders
• Interaction Risk Profile
• Reducing Interaction Risks
• Risk Reduction Streams (1..3)
• Current / Planned Systems
• Journey Map
• External Groups
UNCLASSIFIED
4
Our vision is to be the leading global mining company, by being the investment, the partner and the employer of choice by;
• Portfolio of world class assets
• Organising efficiently and effectively
• Operating safely, sustainably and responsibly
• Employing the best people
One of the world’s largest mining companies.
Focused on operating world class assets in the most attractive commodities:
• Iron Ore and Manganese
• Metallurgical coal
• Thermal coal
• Copper
• Nickel
• Platinum
• Diamonds
Over 145,000 permanent employees and contractors
Operations in Africa, Asia, Australia and North and South America
OVERVIEW OF ANGLO AMERICAN
UNCLASSIFIED
5
The reality
• High Potential Incident (HPI’s) evidence shows that equipment
collisions are a real risk
• Collision avoidance technology as presently deployed is not
adequately effective
The Group requirement
• Integrated collision avoidance and collision mitigation on
SME’s are required for both present and future fleets
• Collision mitigation : when the collision does occur the
consequences are controlled and reduced
• For haul trucks by eg :
– integrated light/heavy bumpers
– cab location/configuration
– active collision avoidance systems integrated into
operator controls
CHALLENGE ON MANAGING TRANSPORTATION RISK
UNCLASSIFIED
6
RP 35 is the Recommended Practice (RP) for selection and assessment of collision
avoidance systems for the Anglo American Group
NON-COMPETITIVE COLLABORATION
UNCLASSIFIED
RP 35 in a nutshell
• Understand and refine the high risk scenarios
• Develop requirements for each scenario
• Analyse gaps in current or new collision
avoidance systems
• Identify and implement improvements with
technology partners
Taking RP 35 to industry
• CRC Mining - Australia
• ISO 17757 and 19014
• RSA – DMR (MOSH)
• Australia – NSW/QLD (MEPIAG)
• OEMs & other mining companies
7
FOUR STEPS...
High
• Establish underlying baseline risk for all scenarios using HPI’s and industry registers
Significant
• Identify other controls (such as separation of traffic) and apply these first
Medium
• Assess effectiveness of existing Collision Avoidance System Controls and Treatments
Low
• Analyse gaps in current Collision Avoidance Systems and implement improvements
Risk Level
1
2
3
4
4 Classes of Controls and Treatments (Preventative & Corrective)
5 Types of Collision Avoidance Systems
66 Classifications of Scenario and Site Requirements
330 Categories to define characteristics of Collision Avoidance Systems
RP 35
1 ZTC
2 SAT
3 PAT
4 PDT
5 CAT
Zone Control
Technology for
managing objects
entering, leaving
or within a zone
Safety Adherence
Technology for
managing
behaviour of
objects within a
zone
Collision
Avoidance
Technology to
actively prevent
collisions between
objects
Proximity
Detection
Technology to
automatically
detect the
presence of
nearby objects
Proximity
Awareness
Technology to
assist an operator
to see nearby
objects UNCLASSIFIED
8
RP 35 PROCESS
Understand and refine the High Risk
Scenarios
Identify and implement
improvements with Technology Partners
Develop Requirements for
each Scenario
Analyse Gaps in current or new
Collision Avoidance Systems
Zero Harm
UNCLASSIFIED
9
APPLYING RP 35
WRAC
Process Flows
Process Deviations
Equipment Activities
Baseline / Now
Risk Exposure
Other
Now
New
Requirements
Identify Critical Controls
Assess Control Effectiveness
Measure / Audit Performance
Co
ntr
ols
&
Tre
atm
en
ts
Risk
Reduction
Realised
New
Risk
Exposure
UNCLASSIFIED
10
RP 35 STAKEHOLDER ROLES
Identify interactions with significant risk
Complete interaction risk matrix
Prepare site requirements from RP 35 classifications
Assess capability of now/new technology
Highlight gaps between requirements and capability
Identify critical controls & evaluate effectiveness / measure-audit
Group BU Vendor
A R -
A R -
A R -
I R C
I R C
A R C
Responsible Assists* Consulted Informed
*Modified RACI – clarifies Accountable-Responsible role differences
UNCLASSIFIED
11
INTERACTION RISK PROFILE
UNCLASSIFIED
Anglo American Group
Iron Ore - Kumba
Iron Ore - Brazil
Metallurgical Coal
Surface
UG
Copper
Thermal Coal
Surface
UG
Nickel
Platinum
Surface
UG
Niobium
DeBeers
Surface
UG
Phosphate
Business Unit RP 35 Interaction Matrices
12
Technology Innovation
Active OTM Community (incl.
OEMs)
Business Unit
Now Technology Selection &
Implementation
OEM Equipment
REDUCING INTERACTION RISK
UNCLASSIFIED
Automation
(Stream 3)
Control
(Stream 2)
Assist
(Stream 1)
Operational Risk Management
Machine Interfaces
RP 35 Group
New / Next Technologies
Roadmap Alignment Support
Services
Future Needs Tolerable Risk Profile - Interactions
“2020” Requirements
Business
Unit
13
• Provides assistance to operator of equipment
• Supplements ‘Other’ controls and treatments to manage risk
• Many OTM ‘After Market’ solutions fitted to mobile equipment
• Focus on ‘soft’ Separation controls : Video-Visual-Voice-Audio alarms
• Use of limited signal / data inputs from machine
• Control of machine via human operator only
STREAM 1 - ASSIST
UNCLASSIFIED
Heavy reliance on administrative procedures
to manage risk
Challenging to provide two Very Effective
controls to mitigate risks in every scenario
with elevated risk levels
14
• OTM ‘After Market’ solutions in development / early stage deployment
• Focus on ‘hard’ Engineering controls to interlock machine
• OEM position on exposing machine controls:
• Underground : Reluctantly working with OTMs
• Surface : Major OEMs are resisting, especially with mobile equipment
• Primary interface to control machine is still via human operator
• Interlocks engage only in specific circumstances
• Reduces risk in specific scenarios
STREAM 2 – CONTROL
UNCLASSIFIED
Regulatory environment changing towards
enforcing minimum levels of control as a
mandatory requirement
Careful assessment of risk is crucial in
decision to deploy / not-deploy
15
• Major OEMs offering ‘closed’ systems on limited range of equipment
• Aftermarket OTM solutions emerging (mostly without OEM assistance)
• Human operator supervises only (no direct control)
• Risk profile dramatically lowered when full automation is cost effective
• Semi-automation offers reduction in risk for specific cases, e.g.
– Auto-steer on haul road incline / decline (e.g. following pantograph)
– Auto-drill
STREAM 3 - AUTOMATION
UNCLASSIFIED
May only be applied to a limited part of the
mobile equipment fleet where the business
case is favorable
OEM closed systems may not be suitable
for many site / operations with mixed fleets
Control interfaces (Stream 2) are critical to
stimulate development of solutions
16
INTERACTION RISK REDUCTION
Business Unit (BU) Surface Underground
Business unit 1 -
Business unit 2
Business unit 3
Business unit 4
Business unit 5
Business unit etc
Business unit etc
Business unit etc
Business unit etc
Business unit etc
U
U
N
U
U : Upgrade planned / in progress
N : New system planned / in progress
C : Currently being implemented
D : In Development / Trials
U
D P
D D C
UNCLASSIFIED
17
Phase 1
(to Dec 2013)
Phase 2
(2014-2015)
Phase 3
(2016-2020)
RP 35 Review (across BUs)
• Interaction Matrix
• Gap Analysis
• Control Effectiveness
Define target equipment based on risk
profile and no.s of equipment (group-
wide)
Specific projects aimed at reducing
interaction risks across AA group
RP 35 OEM Engagement
• Operational Risk Profile
• Control Interfaces
• Agree Way Forward
Specify 2020 objectives for all target
equipment – Assist / Control / Automation
Streams
Validation of performance
RP 35 Industry Engagement
• What’s required?
• Who’s interested?
• What participation?
OEM control interfaces defined and
scoped for future equipment purchases
Control interfaces implemented for all
major OEM equipment
RP 35 Support Services in place
across Anglo American Group Update
of RP 35
Initial equipment arriving with control
interfaces in place / initial systems
Risk reduction realised for all new
equipment arriving on-site
JOURNEY MAP
UNCLASSIFIED
18
EXTERNAL GROUPS
UNCLASSIFIED
ISO •17757
•19014
•UGM Safety
IEC •61508
AS
SANS
South Africa
•DMR (MOSH)
Australia •NSW/QLD (MEPIAG)
South America
•Chile
•Brazil
•Peru
USA •MSHA
Long Term •Industry Forums
•Leader Groups
•Peak Bodies
Medium Term
•OEM Engagement
•Targeted Projects
Lead / Influence
•Conferences
•Expos
Industry
Standards
Regulatory
19
• Project Coordination
• Industry Group Representation
– CEO level
– Delegate level (e.g. Engineering Council)
– Expert/practitioner level
• M&T Engineering
– Group Technical Standards
(incl. update of RP 35)
– ISO / IEC Standards Development
– OEM Engagement
RESOURCES
UNCLASSIFIED
• S&SD Operational Risk Management – Risk &
Assurance
• M&T Technology Development – Automation
Streams
• RP 35 BU/Site Support
• RP 35 Training
Under direction of Transportation Safety Risk Improvement Group:
20
• Interaction Risk is a significant contributor to Anglo American risk exposure
• We are using RP 35 to identify key risk areas and to implement suitable controls for now and future in
a ‘risk driven approach’
• Ultimate objective is for equipment to suitably equipped when it arrives on Anglo American sites
• Expect that more standard types of Collision Management System controls will become standard on
most OEM equipment (e.g. camera, radar where applicable) with simple interfaces initially
• Industry engagement is critical and we are seeking the right support that will foster development of
standards
CONCLUDING REMARKS
SECURITY CLASSIFICATION
THANK YOU
UNCLASSIFIED
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