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Excellence Award
Scott Lowe
BHP Billiton Energy Coal, Melbourne, Australia
Scott Lowe developed and implemented a Fatal Risk Peer Review Program for the Energy Coal Customer Sector Group.
The driver for the project was the unacceptable fatality rate at Energy Coal sites and the need for continual safety improvement if the Company’s target of Zero Harm to people is to be achieved.
The project was undertaken in two phases. Commencing in early 2002, Scott began analysing past safety incidents to identify the causes of workplace fatalities and accidents that resulted in significant injury.
This analysis identified 11 hazard areas across Energy Coal: mobile equipment operations; use of explosives; uncontrolled energy sources; geotechnical; fall of person from height; fall of material/lifting and load security/materials handling; fire; moving machinery; drowning; confined space incidents; and hazardous materials and chemicals.
Once the analysis phase was completed, Scott developed the Fatal Risk Peer Review Program for implementation across all Energy Coal sites. The review system in the program incorporates the Company’s Fatal Risk Control Protocols and builds on existing audit and review processes, particularly the Behavioural Based Safety Observations program.
The Fatal Risk Peer Review Program involves a team of people from a number of sites going to a specific operation to review the adequacy of fatal risk controls at that site and the extent to which these controls are being implemented. Compliance against those controls and the associated requirements is then assessed. A pilot review was conducted at Middelburg Mine in South Africa in May 2002; and, since that time, every Energy Coal asset has had such a review.
The formal Fatal Risk Peer Review Program is now being implemented; and, to date, more than 100 opportunities to reduce fatal risks have been identified. These are being addressed through site action plans.
The program is a valuable knowledge-sharing exercise, enabling sites to exchange a wide range of ideas and information about issues, opportunities and best practice procedures.
The Fatal Risk Peer Review Program is to be conducted at all Energy Coal sites on an annual basis.
Highly Commended
Chris Faure
(Team representative)
Samancor Manganese, MMC Krugersdorp, Gauteng, South Africa
Chris and his team implemented a project that has eliminated the risk of employee exposure to toxic hydrogen sulphide gas. During the last 30 years, the Krugersdorp operation has recorded two fatalities related to the production of ammonium sulphide, which produces hydrogen sulphide in an intermediate step. Ammonium sulphide is a primary reagent in the processing of manganese.
A nearby company was identified as producing an excess of hydrogen sulphide gas from their fuel production plant. During a three-year cooperative project, an off-site production facility was commissioned to utilise waste hydrogen sulphide for the production of ammonium sulphide. This has enabled closure of the sulphide production facility at Krugersdorp.
In addition to the safety benefits, the project has significant economic and environmental benefits. Key learnings for the program have been transferred to the Nelspruit site.
Philip Forster
(Team representative)
BMA Blackwater Mine, Queensland, Australia
Phil and his team were asked to identify and implement new engineering controls for vehicle loading cranes (VLC), in response to a fatality that occurred at the mine in 2002. An operator sustained injuries to his chest when he was trapped against an operator’s control panel by the movement of a VLC jib.
The innovative solution developed by the team reduces the risk of this type of accident recurring by preventing the boom of a VLC from entering the operator’s zone. It addresses the potential for human error by ensuring the crane will not operate unless protective bars are in place. The new control does not reduce the efficiency or function of the VLC and has been fitted to all VLCs on site. Contractors are also fitting the control to comply with BMA Blackwater Standards. These standards are also enforced across all BMA-managed operations.
The effectiveness of the modifications has led to draft changes in the Australian Standard.
Ian Long
(Team representative)
Mozal Aluminium Smelter, Maputo Province, Mozambique
Ian and his team have been implementing a behaviour-based safety program to improve the safety performance at the Mozal 2 expansion project and to help achieve the goal of Zero Harm.
After the expansion project commenced, the Classified Injury Frequency Rate rose to unacceptably high levels. Since the safety program, enhanced in line with the Zero Harm imperative, was introduced at the site in April 2002, the rate has declined significantly, with zero classified injuries being recorded through the months February to June 2003.
The team has achieved this through the implementation of a Zero Harm toolbox, incorporating a wide range of initiatives including visible safety leadership by management; an extensive communication program integrated into day-to-day work activities; multilingual industrial theatre; identification of trends and issues; use of lead indicators; targeted risk activities for rigging, lifting, scaffolding and working at heights; the introduction of compulsory eye protection; and improved safety harness use.
Merit
Bob Myatt
(Team representative)
Appin Colliery, New South Wales, Australia
Bob and the Emergency Escape System team have implemented a system that will facilitate mineworkers escaping in the event of an underground fire or explosion. The system provides individual breathing apparatus, additional compressed air storage throughout the mine, and electronic communications. Using the system, workers can follow lifelines through areas of contaminated atmosphere and poor visibility.
James Pile
(Team representative)
San Juan Underground Mine, New Mexico, USA
James and his team have addressed premature failing of cable trusses by designing a new roof support truss to withstand the effects of corrosive groundwater and hydrogen sulphide that occur at the site, with the aim of reducing the risk of roof falls. The project involved international research and field trials of prototypes. The new truss is also easier and safer to install.
Earl Robinson
(Team representative)
Worldwide Drilling, Houston, USA
Earl and the Houston Drilling Team have achieved an outstanding safety record in the high-risk area of ultra-deepwater drilling. The team managed the incorporation of safety features and systems in the design and construction of a new drillship, the CR Luigs, contracted by the Company for drilling operations. Since commissioning, a comprehensive safety program has been implemented on the drillship.
Phillip Sinel
(Team representative)
Griffin Venture FPSO, Offshore from Onslow, Western Australia
Phillip and his team have developed an electronic version of the Griffin Venture’s Safety Case (a document detailing safety hazards) to replace the existing large paper-based technical document. The e-Safety Case, which was designed in conjunction with on-board personnel, has been integrated into existing job safety analysis procedures and incorporates triggers to promote regular use.
Jody Todd
(Team representative)
EKATI Diamond Mine, Northwest Territories, Canada
Jody and the Open Pit Geology Group designed an innovative ‘draping’ project to maintain the safety of personnel working at the base of a potentially unstable wall in subarctic conditions. The ‘draping’ method used rock reinforcement and a unique anchoring system installed by the Geology Group, Mine Services and the construction contractor. Through a consultative process, employees and government regulators were involved throughout the project.
Peter Whittall
(Team representative)
Dendrobium Mine Project, New South Wales, Australia
Peter and the Dendrobium Mine Project Team have set new safety standards in the construction of a mine ventilation shaft. The shaft, 183 metres deep and 4.25 metres in diameter, was constructed using a blind bore technique, with cement lining sprayed onto the shaft walls to minimise breakaway. The technique negated the need for anyone to enter the shaft during construction, contributing to zero lost time injuries.