Safe to Work January 2024 by Prime Creative Media

ISSUE 29 - JAN-FEB 2024

THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY

2024 | JAN-FEB | ISSUE 29

Eliminate live work

SAFETOWORK.COM.AU

SafeGauge is improving workplace safety by removing technicians from the line of fire

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Comment

Sparking a safety conversation ELECTRICITY IS PRETTY MUCH EVERYWHERE ON A MINE SITE, BUT DO WE PAY ENOUGH ATTENTION TO ITS RISKS?

PAUL HAYES

COO CHRISTINE CLANCY MANAGING EDITOR PAUL HAYES Tel: (03) 9690 8766 Email: paul.hayes@primecreative.com.a ASSISTANT EDITOR TIMOTHY BOND Tel: (03) 9690 8766 Email: tim.bond@primecreative.com.au

rom recharging vehicles to powering workers’ accommodation, electricity is a fundamental part of any mining operation. And with the industry transitioning away from fossil fuels, the role of electricity will continue to grow – and the importance of safety will grow along with it. Electricity can present a significant hazard to workers. Shocks and burns from contact with live wires, fires caused by an electrical fault, and power surges are just a few of the risks. Something as seemingly innocuous as a loose wire can release thousands of high-voltage shocks, and just a solitary spark can wreak havoc on a mine site, where the surrounding environment is often loaded with things like

flammable dust or gas and other accelerants. Electricity doesn’t exactly have a mind of its own, but it will take the path of least resistance. That presents considerable safety issues because, even if it means the electricity has to conduct through the air or a body, that’s what it’s going to do – and there’s little to be done once it gets going. And that’s why awareness and understanding before an incident occurs make all the difference. It’s vital that companies throughout the resources sector consider the risks of electricity when implementing their mine-site safety plans, making every effort to not only educate workers on the dangers, but also minimising the risks on

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

RESOURCES GROUP LEAD JONATHAN DUCKETT Mob: 0498 091 027 Email: jonathan.duckett@primecreative.com.au

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BUSINESS DEVELOPMENT MANAGER NATALIE HERBSTREIT Mob: 0412 741 068 Email: natalie.herbstreit@primecreative.com.au

KELSIE HARFORD Tel: (03) 9690 8766 Email: kelsie.harford@primecreative.com.au CLIENT SUCCESS MANAGER JANINE CLEMENTS Tel: (02) 9439 7227 Email: janine.clements@primecreative.com.au

DESIGN PRODUCTION MANAGER Michelle Weston ART DIRECTOR Blake Storey

SAFETOWORK.COM.AU 3 JAN-FEB 2024

electrical incidents before works even begin. Underground mining, in particular, can present a challenge given the relatively dangerous environments in which it’s done – a place with lots of unavoidable elements like dust and water ingress, which can cause a level of humidity that creates a risk of causing a major electrical fault. But whether on the surface or far underground, electrical safety is an issue to which mine sites across the country should be paying especially close attention. Paul Hayes Managing Editor

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In this issue

Features

12 Work hard, stay safe

48 Mission-critical

for the productivity and safety of any

communication

mining operation.

SafeGauge is taking heavy-vehicle maintenance technology to the next level

Sepura’s communications combine

30 The road to zero

with its MultiTool Pro.

reliability and long range to keep mine

safety incidents

20 Containing the spark

sites connected.

A multifaceted approach to its

Electricity is something of an

equipment is helping Epiroc

underestimated force in the mining

eliminate live work.

industry, and safety measures have their

56 Learning from disasters To foster a true zero-harm workplace, employers need to rely on a tried-and-true

40 A coal comeback

work cut out for them to keep up with developing technology.

method: learning from mistakes.

After closing due to a fire in 2018, Queensland’s North Goonyella coking

24 Safety switch-up

coal mine is set to reopen.

NHP’s TemRack iR is keeping personnel

44 Where production

out of the switchboard room.

and profit meet

28 Making the most of

Martin Engineering examines

maintenance

the way conveyors are specified,

Upholding proper maintenance can

designed, purchased, operated

be complex, but it remains essential

and maintained.

30 REGULARS

3 COMMENT

6 NEWS

10 PRODUCTS

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News Poor lighting ends in excavator rollover A large excavator rolled over on a Queensland mine in September 2023, with investigators pointing the finger at poor lighting and a sub-standard ramp. Resources Safety and Health Queensland (RSHQ) investigated the incident, which occurred on a north-west Queensland mine. As the excavator was ascending a ramp to a bench in preparation to

load trucks, one of the machine’s tracks departed from the ramp. The excavator subsequently rolled off of the ramp and onto its side. The operator was able to escape the cab and was transported to hospital for treatment. RSHQ’s investigation found a number of contributing factors to the accident: the machine was not in the correct configuration for

A large excavator rolled over on a Queensland mine in September 2023.

the ascent (drive motor position); there was limited visibility (before sunrise), no in-pit lighting, and blind spots from the operator’s position in the cab; the ramp was narrower than site specification and was not compacted. Inspections carried out by supervisors also failed to identify the ramp as being outside of specifications. RSHQ recommends sites check the quality of constructed bench access ramps against both site and original equipment manufacturer’s (OEM) requirements; that machines are in the correct configuration to ascend and descend access ramps; better visibility for in-pit operations before sunrise; and that sites incorporate rollover protection structures for mobile equipment, which helps mitigate the risks of an accident. The investigation came just two months after RSHQ threatened to suspend unsafe sites following a spate of dozer rollovers on Queensland coal mines.

Atlas Iron awarded world-first safety rating In a world-first for the mining industry, Atlas Iron’s Sanjiv Ridge iron ore site in WA has been awarded the WELL Health-Safety Rating. The WELL Health-Safety Rating is an annual rating that seeks to empower business owners and operators to prioritise the health and safety of their staff, visitors and stakeholders. Atlas Iron, a Hancock Prospecting company, is the first mine site in the world to be awarded the rating. “(This) reinforces our commitment to prioritising the health, safety and comfort of our people,” Hancock Operations chief executive officer (CEO) Gerhard Veldsman said. “Championed by our executive chairman Gina Rinehart and previous-Atlas CEO,

now Atlas board member, Sanjiv Manchanda, achieving this certification demonstrates that we are putting the wellbeing of our people first, both on site and within the village facilities.” The rating is a subset of the WELL Building Standard, pioneered by Delos, which sets pathways for implementing health-first strategies to support physical and mental health. “We are proud to be leading the charge on implementing this in a non-urban and remote location,” Veldsman said. “[It is] a world first which we are excited to soon extend across Atlas’ other sites.” The rating is made up of six action areas: cleaning and sanitisation procedures, emergency preparedness SAFETOWORK.COM.AU 6 JAN-FEB 2024

programs, health service resources, air and water quality management, stakeholder engagement, and communication and innovation. “Achieving the WELL Health-Safety Rating means a safer, healthier, and more satisfying work environment for employees, with clear benefits such as reduced health risks, improved wellbeing, and a positive workplace culture,” Atlas non-executive chairman Spiro Pappas said. “It reinforces our commitment to our employees’ health and safety. We are proud of Atlas and proud of the efforts of our employees. “Larger corporations tend to treat their projects and even staff as numbers. Here at Atlas, we don’t.”

Fresh warnings over heavy vehicle tyre explosions The NSW Resources Regulator has identified a lack of preparedness and appropriate response to heavy vehicle tyre fires, which carry the risk of explosion, at some mine operations. Owing to their size and construction, heavy earth moving vehicle tyres are susceptible to unexpected explosions when exposed to heat. Debris from these explosions can be projected hundreds of metres and carry enough force to cause severe injury or death. According to the Regulator, recent incidents show the risk of an explosion is not understood or given appropriate concern. In one instance, a fire broke out on a front-end loader at a coal mine.

“Regulator inspectors found the mine did not have a good working knowledge of the risks associated with heavy machinery tyres when exposed to heat and fire conditions,” the Regulator said. “The response to the incident involved staff entering an area that should have been declared an exclusion zone for worker safety.” Another incident involved a fire on a dump truck at a coal mine. “The dangers of hot tyre fires were not initially considered within the emergency response, and watercarts tried to extinguish the fire in close proximity to the tyres in a forwardfacing orientation,” the Regulator said.

“The mine operator had thermal imaging temperature monitoring available, but it was not used for throughout the response phase of the incident. “A supervisor activated the external fire suppression on the truck’s bumper after approximately 42 minutes after the fire began, placing themselves in close proximity to the hot tyres.” The Regulator stressed the importance of mine sites reviewing emergency plans and response procedures to cover the risks involved in firefighting heavy machinery tyre fires.

Why is Glencore closing its Mount Isa mines? After 60 years of operation, Glencore will close its Mount Isa underground copper mines and concentrator in 2025. Despite the Swiss multinational’s best attempts at extending the life of its underground copper mines at the Queensland site, studies and reviews ultimately bore no fruit. “Unfortunately, it has not been possible and they have reached the end of mine life,” Glencore announced in late 2023. “The studies revealed that the remaining mineral resources are not economically viable due to low ore grades and areas where, due to geological conditions, safe extraction can’t be achieved using current technology. “This all coupled with ageing infrastructure.” The development came at a time when copper prices were trending down. The Enterprise, X41, Black Rock, and Lady Loretta mines, as well as the copper concentrator, are all set to be closed in the second half of 2025. Chief operating officer for Glencore’s Australian zinc and copper

assets Sam Strohmayr said that the company will transition its Mount Isa operations to focus on long-life zinc assets. “We know this decision will be disappointing for our people, our suppliers, and the Mount Isa community,” Strohmayr said. “The reality of mining is that mines have a beginning, middle and end. And, unfortunately, after 60 years of operation, Mount Isa’s underground copper operations have now reached that end.

“Our Mount Isa underground copper mines, copper concentrator and supporting services currently employ around 1200 people. “Glencore will continue to invest in the long-term future of Mount Isa Mines, including the George Fisher mine with a current life of mine to 2036, and our zinc-lead concentrator and lead smelter. “We also expect the copper smelter and refinery to continue operating to 2030, subject to approval of additional capital investment.”

Glencore will close its Mount Isa underground copper mines and concentrator in 2025.

SAFETOWORK.COM.AU 7 JAN-FEB 2024

News Incorrectly fitted valve leads to plant explosion Resources Safety and Health Queensland (RSHQ) investigated an explosion that took place at a chemical processing plant in Queensland in September 2023. Workers had just competed routine maintenance and were recommissioning equipment when pressurised hydrogen gas was released, resulting in an explosion and fire. Three workers were injured and the plant was damaged. Fortunately, the workers did not require hospitalisation. RSHQ identified the failure of a high-pressure valve as the direct cause of the incident. The Regulator also indicated that the bearing bush bolts of the valve may not have been correctly installed at the time of overhaul, materially contributing to the incident. In other words, the valve may not have been correctly reassembled after maintenance. The Regulator emphasised the importance of checking correct assembly on high pressure valves following maintenance overhauls. It also called for systems and processes

that ensure quality assurance to be used for the overhaul and testing of these valves; and for the maintenance of the equipment involved in hydrogen usage to comply with original equipment manufacturer (OEM) specifications. According to RSHQ, all site senior executives should: • remember that hydrogen is considerably more hazardous than liquid petroleum gas (LPG), as it possesses a wider explosives range and a lower ignition point, and is more difficult to contain

• employ highly sensitive and specialised detection method, as detecting hydrogen gas leaks can present difficulties, particularly due to its tendency to disperse rapidly • refer to OEM specifications to ensure work methods and testing procedures are suitable for application when working on a hydrogen equipment • ensure suitable trained personnel are engaged in maintenance and quality assurance.

Pressurised hydrogen gas resulted in an explosion and fire at a chemical processing plant in late 2023.

Case closed for runaway radioactive capsule Some nine months after a radioactive capsule the size of a tic-tac fell from a Rio Tinto truck in the Pilbara, those involved are officially out of hot water. The Radiological Council concluded its investigation in October 2023 with no fines or charges being issued. While the details of the investigation will not be revealed to the public for security and safety concerns, WA Health Minister Amber-Jade Sanderson dubbed the incident “a series of unfortunate events”. Sanderson also called clean-up and recovery efforts “very expensive”. The report’s findings have been passed onto Sanderson for review.

The Radiation Safety Act remains under review after it was revealed that the maximum penalty that could have been imposed for the missing capsule was $1000, an amount dwarfed by recovery costs and the potential risks posed to the public and the environment. The caesium-137 tablet disappeared for more than a week on a 1400km stretch of the Great Northern Highway in January 2023 after it fell off a truck travelling from a Rio Tinto mine in the Pilbara. The caesium-137 tablet forms part of a radiation gauge commonly used in processing plants. The gauge has since SAFETOWORK.COM.AU 8 JAN-FEB 2024

been banned from sale in WA. The capsule emits beta and gamma ray, with health authorities warning that standing within a metre of the capsule is the equivalent of receiving 10 chest X-rays in an hour. As for how the capsule escaped from the truck, the theory among authorities is that the container housing the capsule unit collapsed in transit due to road vibrations, and the unit fell through a hole left by a dislodged bolt. Remarkably, the 8mm capsule was subsequently discovered by search teams, which WA Emergency Services Minister Stephen Dawson likened to finding a needle in a haystack.

Expect more at every stage of tyre life

Kaltiremining.com

Making tyre management safer and more productive. Reducing total cost of ownership and putting ESG at the core of our offering. By delivering more than what is expected, we help make a difference every day.

Products CRITICAL COMMUNICATIONS Sepura, a UK-based company with over 20 years’ experience in mission-critical communications, has launched a new suite of TETRA products tailored to the mining industry: • VHF hand-held and vehicle devices, offering superior range and lower base station density, reducing costs • SC23, a robust handset with a simplified user interface that uses existing SC20 accessories • Ultra CSM speaker microphone, which uses anti-magnetic technology for iron ore sites, where metallic particle ingress can impact product life and performance Sepura’s design philosophy is to provide comprehensive solutions for customers. Its focus in the mining sector is robustness, with radios and speaker microphones being easy to maintain, rated to a minimum IP67 ingress protection and featuring Sepura’s unique water-porting technology. This means minimal degradation in audio clarity or loudness when exposed to driving moisture. • sepura.com/industries/mining

SHINING THE WAY The Wisdom 6A cordless LED cap lamp from Perfect Image is a water-resistant, USB rechargeable unit with a nickel-adjustable bracket that is powered by two Panasonic 3.5-volt Li-ion batteries. The lamp is ATEX ia Ma and IECEx Ex ia Ma certified and features a high (240 lumens) and low (50 lumens) lighting mode. It’s rated capacity is 7000maH with a high-beam distance of 220m and lowbeam distance of 85m. The lamp’s run time is 13 hours in high mode and 60 hours in low mode, with a battery lifecycle of 1200 cycles, a charge time of 5.5 hours and a weight of only 169g. The Wisdom 6A is distributed by Perfect Image, which is continually expanding its product range and by directly importing its product line can meet the needs and demands of small and large customers. An extensive range of lighting and charging products is available throughout Australia and New Zealand and can be sourced from a network of distributors, resellers and major retailers. • pii.net.au

PROTECTING 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, high-impactabsorbing polymer system. According to Rattlejack, 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. It has been purpose-built to activate on impact with any downward force: its unique 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. • rattlejack.com.au

MAKING MINING SAFE WITH THE BOLTEC M BATTERY Epiroc is leading the charge towards sustainable mining with the Boltec M, a fully mechanised bolting rig with battery driveline. Capable of handling most bolt types between 1.5–3.5m, including friction, inflatable, mechanically anchored and rebar bolts, the Boltec M is among the most advanced and productive fully mechanised rock bolting machine in its size class. The optimised bolting unit with reduced feed length enables reduced drive sizes while retaining the same bolt lengths used previously. The Boltec M series machines share a common 4WD articulated carrier design with their Simba mining and exploration (M&E) and Boomer M&E stablemates, which ensures easy maintenance due to an open service architecture. The standard and optional features of the Boltec M ensures operator safety and comfort and guarantees a job well done while the battery driveline reduces the environmental footprint and creates a healthier work environment. • epiroc.com/en-au

SAFETOWORK.COM.AU 10 JAN-FEB 2024

THE NEXT LEVEL IN WEAR PLATE PERFORMANCE Hardox 500 Tuf is the latest upgrade in the Hardox range. It delivers high-strength, extreme hardness and toughness in one and the same wear plate. Hardox 500 Tuf combines the best properties from the Hardox 450 and Hardox 500 grades. It has the toughness necessary to perform as a structural material in heavy-duty tipper bodies, containers and buckets. It also works in freezing conditions, as the impact energy values indicate. Superior wear and dent resistance gives extended service life and the ability to endure heavy impact. Typical working conditions include loading and unloading of heavy and sharp rocks in quarries and mines, handling large and heavy steel scrap, and in demolition when pieces of concrete with rebar are loaded or dropped into tippers. • ssab.com/en/brands-and-products/hardox/product-program/500-tuf

DON’T LET DARKNESS STOP YOU The Atlas Copco HiLight B5+ Light Tower is suitable for a wide range of applications, including events, residential construction, 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 and 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 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. To find out more, contact your nearest Atlas CEA branch. • atlascea.com.au

SUPERIOR WEAR RESISTANCE The attributes of rubber and ceramic wear liners are well known in the industry today. Rubber wear liners provide excellent abrasion resistance and impact resistance for various applications in the mining and mineral processing industry. Traditional ceramic liners provide an even higher level of wear resistance, albeit at the expense of impact resistance Tega Losugen, Australia’s range of Aggression wear liners, is widely used across various applications in mining processing. Its state-of-the-art water cutting services ensure tolerance precision across its rubber liner range,including a recent reline of a nine-tonne conical trunnion at a nickel mine in Western Australia. The Aggression Prime liner is part of Tega’s extensive Aggression wear liner range, which also features rubber, ceramic and UHWMPE wear liners in a range of sized to suit requirements. • tegaindustries.com.au

COMFORT AND PERFORMANCE Bollé Tryon range of glasses are available in three versions: safety spectacles, OTG and prescription. The glasses are ultra-wrap-around with a sporty design and are non-slip, providing a safer experience. Like many Bollé products, the Tryon range is available in clear, smoke, copper, cobalt flash and polarised lenses, making them an ideal choice for use throughout a range of industries. The cobalt flash lenses are suitable to use outdoors and indoors, as they protect the wearer from heat, while the copper lenses are ideal for activities that require exposure to alternating high and low light. Like all of Bollé’s products, the Tryon range of classes combine style, innovation and protection to provide the wearer with the maximum comfort and safety. • www.bolle-safety.com/au/industrial/glasses/safety-glasses/tryon-TRYON_

INDUSTRIAL.html

SAFETOWORK.COM.AU 11 JAN-FEB 2024

Maintenance

Work hard, stay safe

SAFEGAUGE IS TAKING HEAVY-VEHICLE MAINTENANCE TECHNOLOGY TO THE NEXT LEVEL WITH ITS LATEST INNOVATION, THE MULTITOOL PRO.

espite being almost five years old, in many ways Australian-owned safety solutions company SafeGauge is only just getting started. “Our goal is to eliminate live work – we are taking people out of the line of fire with our products,” SafeGauge general manager Greg Sweeney told Safe to Work. After making a name for itself in Australia, SafeGauge is working to expand its reach far beyond domestic shores. “We have a number of distributors in the US, Canada and South Africa,” Sweeney said. “We are also continuing to expand further into South America.

“We’re a fairly young company – we had our first sale in 2020 – but we want to continue pushing the envelope in terms of quality, innovation and growth.” In 2020, SafeGauge released the first product in the SafeTest range,

the SafeTest PT (pressure transducer) Series, which allows technicians to monitor the pressure of hydraulic

SAFETOWORK.COM.AU 12 JAN-FEB 2024

The MultiTool Pro can connect and monitor up to 12 SafeGauge sensors at once.

The MultiTool Pro is to be used alongside current and future SafeGauge products.

The MultiTool Pro is flexible and fit-for-purpose.

and pneumatic systems safely and efficiently. This was followed in 2021 by the SafeTest DI (dial indicator) Series, which remotely measures clearances, tolerances and wear on machine components, and in 2022 the SafeTest TM (tachometer) Series, which enables completely wireless RPM measurement. Since its inception, SafeGauge has been recognised for its groundbreaking products and solutions. The company won the New South Wales Small Business of the Year category at the 2022 NSW Minerals Council Industry and Suppliers Awards, and has been acknowledged through other awards like the 2022 Good Design Awards (GOLD), the 2022 HMA (Hunter Manufacturing Awards) Award for Excellence in Product Design, and the APAC Insider Award for Safety Tech Innovation of the Year. In 2023, SafeGauge was recognised by the Resource Equipment Innovation Award at the CORE Innovation Hub Hot 30 Awards and named as a finalist in the 2023 Australian Mining Prospect Awards,

Austmine Awards, and the Hunter Safety Awards. “We plan to uphold that high standard of innovation and quality whilst continuing to grow the business,” Sweeney said. SafeGauge has demonstrated that standard by becoming ISO 9001 certified and partnering with various original equipment manufacturers (OEMs) and mine sites to implement the elimination of live work. The MultiTool Pro first entered the Australian mining market in November 2023 and is the latest innovation in heavy-vehicle maintenance technology. Users can safely, efficiently and accurately log and report readings across a range of vehicles for routine and unplanned maintenance. The tool features an intuitive touchscreen interface that allows technicians to seamlessly connect and monitor up to 12 SafeGauge sensors, including the SafeTest pressure transducers, dial indicators and tachometers, simultaneously from up to 100m away, helping to keep people out of harm’s way.

SAFETOWORK.COM.AU 13 JAN-FEB 2024

Maintenance

The MultiTool Pro records data measured by SafeTest sensors, including the dial indicator.

“The MultiTool Pro is an evolution of our wireless MultiTool,” Sweeney said. “What the MultiTool Pro does is add another layer in reporting, analysing and forwarding data to thirdparty systems, and provides a greater analysis and in-depth record of files from the machinery that has been worked on. SafeGauge developed the MultiTool Pro software solution over a seven-month period. It was built to be flexible and fit-forpurpose, and to provide the highest customer return. “All of SafeGauge’s products use Bluetooth, and that’s how we’re able to get the operators and engineers out of the line of fire,” Sweeney said. “In the past, workers were on the machine, inside the engine bays or, in some cases, underneath machinery when testing different components. “Bluetooth allows those devices to transmit and record the data that’s

“Bluetooth allows those devices to transmit and record the data that’s been measured by the pressure transducers, dial indicators or tachometers as part of their testing process. That’s the real benefit.” been measured by the pressure transducers, dial indicators or tachometers as part of their testing process. That’s the real benefit. “Simply put, it removes technicians from the machine proximity while undergoing routine maintenance such as pressure testing, measuring tolerances and fan speed, collecting valuable data from each test.” With the data collected, the tool can create comprehensive reports with detailed notes, tolerances and sensor comparisons, aiding mining companies in their record-keeping and decision-making.

These reports can be exported and shared through the tool’s in-built cloud connectivity via mine site Wi-Fi or included data sim, helping facilitate collaboration across different teams. The MultiTool Pro can also create custom templates to save to the device’s library for easy and repeated access. And SafeGauge promises there is more to come as it further develops and improves the product on an ongoing basis. “The MultiTool Pro is not a static product,” Sweeney said. “It will be updated regularly with new releases,

SAFETOWORK.COM.AU 14 JAN-FEB 2024

CMY

including new features and feature understands the benefit of eliminating enhancements, which can be live work and the inherit risks in the remotely updated. current practices worldwide.” “I’m not aware of any other Initial feedback on the MultiTool company that offers the standalone Pro has been positive, with customers and detailed reporting of data seeing the added benefits and on our level. It’s fully supported features, and how it will assist them in and developed by our in-house their operations. engineering team based in Australia.” “I know that whenever someone The MultiTool Pro, along with other sees it, they love it, they see the SafeGauge products, will continue value in it because they know to be developed based on customer the SafeGauge brand and like feedback. It will not replace the the reliability of our products,” standard MultiTool, but rather act Sweeney said. as a complementary product with Sweeney believes the MultiTool Pro additional features. aligns with SafeGauge’s motto: work “All our products evolve from hard, stay safe. customer feedback regarding how “I see the MultiTool Pro as being we can improve and enhance the the cornerstone of our products going product,” Sweeney said. forward, as it works with all our current “Our founder and managing and future products,” he said. director Luke Dawson started on the “We are currently on schedule to tools. That’s where he got a lot of his release a few new products in 2024, inspiration and ideas when developing and they will all tie into the MultiTool 12-1_STW_InsertV1.pdf 12/4/23 the initial product (PT1Series). He 11:32 AM Pro. We’ll continue to add features to

the MultiTool Pro as it matures and new products are released over the coming years. “Our priorities are definitely driven by customers. “Coming in 2024, there will be improvements and enhancements to all of our products, including a laser displacement device used for measuring slew wear.” Above all else, SafeGauge wants to continue growing while becoming the safety and maintenance standard not only in Australia, but around the world. “When it comes to elimination of live work, we are looking to expand to other industries outside of mining such as construction, agriculture and defence,” Sweeney said. “There’s a lot ahead for SafeGauge in expanding our footprint, but our main goal is to be seen as the quality and innovation leader and to deliver continuous value to customers who use our products.”

™ ™ ■ ■

■

CMY

Maintenance

Raising the bar on safety NIVEK INDUSTRIES IS MAKING MAINTENANCE SAFER WITH BIG TED.

aintenance is an essential part of keeping operations up and running on a mine site. The sheer size and complexity of mining industry equipment means maintenance can also be dangerous. That’s why Nivek Industries’ new, larger Tracked Elevating Device – Big TED, for short – was created. With a lifting capacity of three tonnes, Big TED is making maintenance work safer and easier on workers. “With Big TED, you don’t need a Bobcat, a crane or a forklift. Big TED will carry the load, lift it, and hold it in place while equipment is installed or uninstalled,” Nivek general manager Derrick Cant told Safe to Work.

VERSATILE

Where Big TED truly shines is in its versatility, helping customers meet their specific maintenance requirements.

Big TED has a lifting capacity of three tonnes.

The team at Nivek is able to design and build custom attachments for Big TED to help customers carry just about anything. Attachments can be designed for applications such as haul truck front hub and brake discs, drill rig fuel tanks, front loader belly plates, and grader tyres, to name a few. And what Nivek Industries doesn’t already offer, it designs at the request of its customers. “The true value of Big TED is in the attachments, which allow it to do multiple tasks. It’s a versatile machine you can use every day for different jobs,” Cant said. Big TED also has an AUX power supply built into the table, allowing the development of smart manoeuvrable attachments that can still be operated via the remote controller, allowing the operator to maintain a safe distance. “If you need something that can tilt a component to a certain angle or

A conveyor headshaft attachment for Big TED.

roll something into a certain position, we can build that into the attachment,” Cant said. Big TED is a veritable Swiss army knife when it comes to mine maintenance, and Nivek Industries is so confident in its product that the company does on-site demonstrations for serious customers.

SAFER

Big TED features dual emergency stops on the machine and the remote control, allowing operators to quickly stop any movement if needed. The joystick-activated remote control allows operations to stand at a safe distance while these heavy components are being moved or lifted into position, removing them from the line of fire if the load happens to fall. Big TED also has a built-in side shift and powered turntable, so workers don’t have to manually handle the load when lining up bolts. This significantly reduces the risk of manual-handling-related injuries. Big TED also features a tilt sensor to reduce the risk of overbalancing, and load cells incorporated into the table to notify operators of overloading. By reducing manual handling tasks, Big TED is making maintenance physically easier for workers, thus preventing fatigue. With Big TED, Nivek Industries is providing the mining industry with a versatile safety tool for maintenance.

SAFETOWORK.COM.AU 16 JAN-FEB 2024

Introducing the New Maximise Safety

Take Elimination of Live Work (ELW) to the next level, with a range of new features designed to help heavy-vehicle maintenance technicians work smarter, and stay safe.

Eliminate Live Work

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Maintenance

Hands-on support

KITO CROSBY AUSTRALIA IS BACKING ITS HIGH-QUALITY HOISTING PRODUCTS WITH TRAINING COURSES FOR ITS DISTRIBUTORS AND END USERS.

ith a long history of manufacturing specialised lifting solutions, Kito Crosby Australia operates with a focus on functionality, safety and durability. Hoists support mining and other industrial operations all around Australia, and that means the maintenance of these assets is vital to operational success and safety. “Regular maintenance ensures that hoists operate safely, reducing the risk of accidents and injuries,” Kito national hoist specialist Glenn Morgan told Safe to Work. That’s the reason Kito Academy was established – to train sales teams, technicians and end-users on best practice when it comes to all things hoists. One of the three pillars of Kito Academy is the Repair Demonstration Clinic (RDC). RDC is designed to provide service technicians, mechanics

People from all walks of a business have something to gain from Kito Academy.

Proper maintenance minimises downtime, ensuring that hoists are available when needed for critical tasks.

and operators with the skills and knowledge to inspect, repair and test Kito’s range of lever hoists and manual chain hoists.

This hands-on session is a combination of theoretical and interactive training modules that teach the basics of maintenance and repair. The program covers modules such as inspection classification, required maintenance work, and preoperational checks. Participants are instructed in the correct methods of disassembly, reassembly and testing to ensure the hoists are operating correctly. This is designed to provide people with an opportunity to get to know the Kito products and their quality down to the smallest detail. “RDC helps to provide maintenance staff with the necessary preventive maintenance and troubleshooting skills they need to ensure any unforeseen or sudden breakdowns can be quickly resolved,” Morgan said. The Safety Operation Session (SOS) is aimed at hoist operators,

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T N • • •

operations managers, safety officers and technicians. SOS focuses on safety in the workplace, correct use of hoisting equipment, examples of how not to use the hoisting equipment, and how to conduct a pre-operational inspection of hoisting equipment and

“Participants in these training courses can expect expert instruction from instructors who are knowledgeable about hoisting equipment and safety procedures.” The third and final pillar is the Product Academy (PA), designed to give distributors and customers a

“Participants have the opportunity for practical, hands-on training with Kito hoisting equipment through [the] Repair Demonstration Clinic and Safety Operation Session.” ensure they are conducted correctly to ensure compliance with AS 2550.12011 – Section 7.3.2. “Participants have the opportunity for practical, hands-on training with Kito hoisting equipment through RDC and SOS,” Morgan said.

better understanding of the product range, comparisons to competitor product, and the benefits of the Kito range. PA is aimed at ensuring customers get the right hoist for the job, highlighting Kito’s dedication to its customers.

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Kito Academy is backed by the company’s range of premium-quality and maintenance-friendly hoists. Kito hoists combine high-quality materials, precision machining, modular design and a slew of other intelligent features to help make maintenance a breeze. “Kito hoists feature an advanced predictive maintenance system, providing easy access to critical components for simplified inspection and servicing by technicians,” Morgan said. “By incorporating these elements into our hoist designs, Kito aims to make maintenance as straightforward and efficient as possible, minimising downtime and ensuring the longevity and reliability of our products.” Kito Academy courses run throughout the year and take place at various locations, including on-site and at the company’s training centres in Melbourne, Perth and Queensland.

Electrical safety

Containing the spark ELECTRICITY IS SOMETHING OF AN UNDERESTIMATED FORCE IN THE MINING INDUSTRY, AND SAFETY MEASURES HAVE THEIR WORK CUT OUT FOR THEM TO KEEP UP WITH DEVELOPING TECHNOLOGY.

t’s a dangerous job, but someone has to do it. Collisions, explosions, caveins, flooding, accidents with heavy machinery. There are any number of reasons you need to keep your wits about you on a mine site. But there’s one unseen danger that could be the difference between injury and going home safe at the end of the day: electricity. A loose wire or faulty conductor can unleash thousands of highvoltage shocks, but even a single spark can wreak havoc in an environment full of flammable dust or gas and other accelerants. Powering everything from tools to lights to vehicles and machinery, electricity is usually a safe and reliable source of energy, but mine conditions can be unpredictable and quick to change. Electricity takes the path of least resistance, and if that means conducting through the air or a body, there’s little to be done once it gets going. But it’s awareness and understanding before an incident occurs that makes all the difference.

A current will not flow unless it has a complete circuit, which is where grounding comes into play. Should a short circuit occur, electricity should just flow into the ground, but if the air is full of flammable dust or thick with humidity, grounding alone might not be enough to protect a worker. That’s why mine operators need to go above and beyond by implementing measures that not only educate workers on what to look out for, but also minimise the risks of electrical incidents before works even begin. Australians are lucky that high safety standards and regulations keep incidents to a minimum but accidents still happen, and some of the most common causes of electrical hazards occur from using electrical tools in damp environments. Underground mining is especially vulnerable in the regard, as unavoidable elements like dust and water ingress cause a level of humidity that creates a risk of causing major electrical fault. It’s an issue to which mine sites across the country should be paying attention. In 2021–22, the Western Australian Department of Mines, Industry

Regulations and Safety reported its safety and health snapshot in which 601 notifiable incidents of electric shocks were reported on mine sites. While there were only four injuries and they were all classed as minor, the report found 88 of those 601 incidents had “strong potential” to result in injury. That’s why the impacts of electrical incidents shouldn’t be underestimated – even a small shock can have dire consequences. Aside from burns, an electric shock can cause seizures, breathing problems and even cardiac arrest. Issues such as pain, numbness and difficulty moving limbs most commonly abate, but in some instances they can be permanent.

STAYING INFORMED

To help educate mine workers on the danger, conferences and seminars are held every year to raise awareness and discuss methods of reducing the likelihood of an electrical incident. In New South Wales, the Electrical Engineering Safety Seminar is the place to be, while the sunshine state has the Queensland Mining Industry

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Arc flashes can vaporise metal and wreak havoc in underground mines.

Health and Safety Conference, but perhaps the largest electrical safety thinktank lies in the mining capital of Australia. The Mine Electrical Safety Conference was held in Western Australia in November 2023, when more than 40 exhibitors delivered technical presentations to representatives from government departments, consultants, suppliers and key industry decision-makers. It was an electrical safety extravaganza that covered two days of technical discussions of all things mine safety. On the docket for 2023 was a specific focus on arc flashes. But what is an arc flash? It’s more than a simple short circuit, that’s for sure. People know that electricity poses a significant risk to workers, but shocks and burns are just the start. An arc flash occurs when a surge of electric current leaves its intended path due to a fault, causing an uncontrollable explosive burst. The result is an explosion hot enough to vaporise metal. Reaching temperatures of up to 19,000°C in

an instant, a surge is hotter than the surface of the sun. As if the heat wasn’t enough, an arc flash releases a projectile pressure with over 1100km/h of force – more than enough to throw a worker across a room. Electrical wires and fittings need to be inspected regularly to avoid shocks and burns.

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There are many causes of an arc flash that workers need to understand. Touching a test probe to the wrong surface or loose connections are obvious sources, but even dust in the air can cause a charge that leads to an arc flash – conditions almost

Electrical safety impossible to avoid on a mine site if proper measures aren’t taken. So what’s being done? Every Australian state and territory has rigorous standards for maintaining electrical safety. WA and NSW have an Electricity Act 1945, while Queensland has the

the switch to less emissions-intensive power sources. While the technology is only getting better, electrical safety is dependent on people having the knowledge and accountability to make sure operations run safely. And legislation needs to keep up.

An arc flash occurs when a surge of electric current leaves its intended path due to a fault, causing an uncontrollable explosive burst. Electrical Safety Act 2002. Victoria has the Electricity Safety Act 1998, and the Northern Territory has the Electricity Reform Act 2000. But a lot can change in 20 years, let alone 80. Mining technology is progressing every day, but its reliance on electricity is only increasing. This is especially true as operators make

Amendments to various electrical acts are implemented every few years. Earlier this year, for example, Safe to Work reported that the Queensland Government is considering 83 recommendations to its Act – but it’s up to the mines to ensure practices are kept up to scratch.

STAYING UP TO DATE

It’s important that mine operators are regularly reviewing their electrical safety plans and updating them based on the live conditions of the mine. WA’s safety and health snapshot found 28 per cent of mine managers had not provided a written summary of responsibilities and duties when it came to electrical safety, and 31 per cent of entries made in electrical logbooks were not properly completed. Rio Tinto is one industry leader saying that that’s not good enough. The major miner is taking steps to address all facets of electrical safety, including arc flashes. “At all times, the elimination of risk is the priority,” the company said. “There must be task and equipmentspecific competency standards and procedures for all electrical work.” Rio’s equipment is regularly inspected and workers are given specific electrical safety training

The underground mining environment is vulnerable to electrical safety incidents.

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before they even set foot on site, with training updates mandatory. Rio Tinto also has a framework set out in its electrical safety standard for situations like incorporating new or modified equipment onto its sites that aims to minimise the risk of electrical incidents. Having put an arc flash and shock protection plan in place, workers have clear definitions of personal protective equipment (PPE) requirements and what to look out for on the job. With coal mines being particularly vulnerable to electrical incidents, Glencore is another big-ticket miner with a solid plan for minimising electrical risk. The company has rigorous standards in place for assessing the risk of electrical incident before work even begins and continues to monitor controls between check-ups. PPE and training are also top priorities for Glencore, with refresher courses in electrical safety ongoing.

All equipment needs to be tagged and tested to the latest electrical safety standards.

With sites being such busy, loud, hot places to work, strong processes are necessary to mitigate risk – everyone needs to be on the same page. That’s why when it comes to electrical safety on mine sites,

good governance is key to keeping workers safe. Whether mine operators or legislators, electrical risks need to be taken seriously by leaders ready to keep up with an industry only just getting started with electrification.

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Electrical safety

NHP’s CUBIC Modular Outdoor system is designed for harsh Australian conditions.

Safety switch-up

NHP’S TEMRACK IR IS KEEPING PERSONNEL OUT OF THE SWITCHBOARD ROOM

s the mining industry transitions to clean and renewable energy, more aspects of operations are becoming electrified. But while electricity is the way forward in terms of sustainable mining, it also represents a safety hazard to workers that needs to be controlled. There are many risks associated with electricity, but none make such a terrible impression as an arc flash, a phenomenon where a flashover of electric current causes an explosion of energy. Arc flash temperatures can reach thousands of degrees Celsius, with a significant range of effect. Owing to the sudden release of high heat – likened to a bomb – they can also be fatal to workers.

According to the Department of Mines, Industry Regulation and Safety in Western Australia, around 25 significant arc flash incidents occur each year on the state’s mine sites. “Mines can be quite prone to arc flashes because they’re dirty, they’re dusty, and there’s lots of vibration,” NHP Electrical Engineering Products business development consultant Jeff Davis told Safe to Work. “There’s lots of things that could go wrong.” Davis has been on committees to design electrical standards including EL-06-08 Switchboards, EL-001 3000 Wiring Rules, EL-001-17-01 Construction and Demolition, EL001-17-02 Transportable Structures and EL-007 High Voltage Switchgear. He said the threat of an arc flash is

compounded in switchboard rooms, which on mine sites are often narrow spaces – not ideal when confronted with the risk of an electrical explosion. But the TemRack iR by NHP is changing the game. When it comes to switchboards, an air circuit breaker (ACB) is often used as the key protection device allowing power into a building. TemRack iR has an automated racking function that permits safe isolation of the ACB, meaning there is no physical interaction between workers and the live ACB. “The riskiest time during any switchboard’s life is racking components out, and an ACB is meant to be racked out. In Australia, that is statistically where the vast majority accidents occur,” Davis said.

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The NHP team servicing a retrofitted TemRack iR.

“The TemRack iR allows personnel to turn the ACB on and off and rack it in and out all while outside the switchboard room. “That way we can keep people completely out of the danger zone.” The TemRack iR is designed with no live parts exposed, minimising the risk of electrocution during racking. “It’s just a matter of going into the room and swapping out the ACB. Then you can leave the room, rack the new ACB and switch it on remotely,” Davis said. The fact the TemRack iR is encased with the ACB means maintenance is significantly safer. “All the working components are in the body of the ACB, so there’s nothing left in the switchboard that needs to be maintained in any way, shape or form, meaning personnel don’t have to make contact with it,” Davis said. “Not only in this a huge safety benefit, but it also gives mine sites 100 per cent uptime of their switchboards.”

The NHP service team offers a host of on-site service options, including power quality, ACB, MCCB commissioning, service and maintenance.

Thanks to TemRack iR’s selfcontained design, NHP can easily retrofit these remote rackers to Terasaki TemBreak AR ACBs, a service companies across the Australian recourses sector have been lining up to access. “It’s been a hit in the mining industry because everyone is pushing to get people out of the switch rooms,” Davis said. “On a mine, unlike in other applications, these rooms can be entirely containerised. If something goes wrong in these small spaces, it can be catastrophic.” NHP has a nation-wide network of service technicians and application engineers to help integrate and maintain the TemRack iR at even the most remote mine sites. Beyond the TemRack iR, NHP offers an entire suite of electrical solutions suited to the mining industry. Concept Tough is NHP’s heavyduty distribution board specialised for rugged Australian conditions. “Mine sites present so many unique and problematic factors, like excessive

dust,” Davis said. “Dust can build up and the sheer weight of it can damage the panelboard. “We have spent an enormous amount of time looking at common materials around Australian mine sites and designed the Concept Tough to keep dust from building up.” Davis said the mounting points of Concept Tough are also uniquely external, which keeps dust out of the box. NHP also recently launched the CUBIC Outdoor Modular, a modular switchboard system that can be built up. “The CUBIC Modular has been specifically designed to stand out in the sun with 50°C beating on it all day while the electrical equipment inside can run safely without overheating,” Davis said.

A TRUSTED PARTNER

It’s not just electrical safety that NHP can help with. The company is an exclusive distributor and service provider of Rockwell Automation

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Electrical safety products in Australia. Known for its industrial automation and information solutions, Rockwell is considered a giant in the resources industry. In the context of mining, Rockwell’s solutions include remote asset monitoring, control systems for mineral processing and metal refining plants, automation solutions for material handling, general mine digitalisation, and much more. “Our technicians and engineers, based all around the country, can also service Rockwell Automation products,” NHP safety and sensing product manager Stefan Stainwall said. “All the work we do comes with rigorous training from Rockwell. Our engineers work at a standard enforced globally by Rockwell Automation, which is a $10 billion company and growing. “As part of that partnership, we’re also able to provide machine safety

risk assessments in accordance with Australian Standard 4024, which provides detailed guidance on how to ensure machinery has suitable levels of functional safety.” Rockwell is also a provider of industrial cybersecurity services, an area where Stainwall said NHP has seen a great deal of movement. “Cybersecurity has become a hot topic in the mining industry in the last year or so following a few security incidents,” he said. “A data breach can shut down operations very quickly, and it’s very costly to fix. “That’s another area where NHP can help the mining industry.” From optimising mining operations with Rockwell Automation solutions to protecting workers against arc flashes with the TemRack iR, NHP’s presence in the resources sector is as broad as it is impactful.

The NHP service team conducting night works at a site.

SAFETOWORK.COM.AU 26 JAN-FEB 2024

TemRack iR is a fully integrated automated ACB racking device.

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Maintenance

Making the most of maintenance UPHOLDING PROPER MAINTENANCE CAN BE COMPLEX, BUT IT REMAINS ESSENTIAL FOR THE PRODUCTIVITY AND SAFETY OF ANY MINING OPERATION.

s machinery and technology evolve along with the resources sector itself, one thing will remain a constant: the need to undergo maintenance. And that process needs to be safe. Maintenance – in the context of the resources sector – refers primarily to the protection and preservation of machinery, vehicles, equipment and associated parts. Maintenance is vital to the productivity of any mining operation – it typically makes up 30–50 per cent of a mine site’s costs, and a large portion of profits will go back into preserving and maintaining the equipment used daily.

Maintenance is also considered the biggest variable cost in almost every operation. Without it, the asset cannot realise its necessary functions within the desired lifecycle and a mine’s production will face unnecessary breakdowns, downtime and costs. But perhaps the most important aspect of maintenance is the simplest: safety. Without regular maintenance, machines break down, and that can cause accidents, injuries and, in extreme cases, death. But maintenance processes are almost always complex, since the operator must try to balance reducing costs with never compromising the asset’s reliability, availability and safety.

Ongoing maintenance upholds the safety of people and machinery.

This balance can be difficult to maintain, but carrying out regular and ongoing maintenance is ultimately less costly, and much safer, compared to unexpected breakdowns or a workplace accident.

BENEFITS OF MAINTENANCE

Proper maintenance allows operators to identify current and potential issues, such as premature wear and tear, leaks or damaged components, more quickly so they can be rectified before the issue escalates. And it’s not just potential equipment issues that can stem from improper maintenance; workers can get caught in the line of fire, too. Daily maintenance helps to ensure faulty equipment doesn’t lead to accidents and human injuries. During 2021–22, 12.8 per cent of serious work-related injury and illnesses reported by Safe Work Australia came from machinery operators and drivers. This equates to 16,200 claims coming from the occupation. And according to a Resources Safety and Health Queensland investigation, two thirds of these finger injuries in 2023 occurred during maintenance tasks carried out on coal mines, with the remaining third involving workers operating plant or undertaking manual handling tasks. The injuries were often preventable and were occasioned due to inadequate job planning and provision of suitable tools. Other common factors included inadequate risk assessment and implementation of controls, inexperience coupled with inadequate supervision, poor communication

SAFETOWORK.COM.AU 28 JAN-FEB 2024

between workers and supervisors, and failure to follow procedure. Irregular maintenance can also lead to a decrease in machine productivity, in turn meaning workers will have to pick up the slack. This can potentially lead to people stepping in to do a job with which they are not familiar, increasing the risk of accidents. An increase in tasks, especially those on which an employee hasn’t been trained, can also lead to burnout, meaning workers will need more time off. In short, it’s not hard to see the benefits of maintenance on a mine and its workforce as a whole. Inspecting critical components of machinery on a regular basis means operators can minimise downtime while maximising efficiency and productivity. But despite productivity being a priority of any mining operation, it is not possible without the people working on the machinery. And if the safety of those people is compromised, it can lead to significant injury and even loss of life. In much the same way regular maintenance means machinery can last longer, checking for potential hazards like loose parts, malfunctioning safety features or compromised structural integrity means operators are empowered to take immediate action and eliminate safety risks before accidents occur.

TYPES OF MAINTENANCE

Mining companies can carry out a variety of maintenance processes and perhaps the first among those is regular inspections, which can detect signs of leaking, wear, damage, strange noises, vibrations, performance issues, and any other abnormalities. However, the first step of any maintenance process should be troubleshooting, which refers to determining why something isn’t working as expected and ways to resolve the problem. Operators can try to analyse the problem by reading equipment manuals, troubleshooting guides, or online resources. Following step-

Without maintenance, an asset can’t realise its necessary functions efficiently.

Maintenance typically makes up 30–50 per cent of a mine’s costs.

by-step procedures can identify the root cause of the problem and offer possible solutions without having to pay for external professional help. As such, original equipment manufacturers (OEMs) will often provide after-sales support. Caterpillar dealers, for example, offer planned equipment maintenance services and unexpected repairs that can be undertaken when it is safe to do so. “That value shouldn’t change throughout the equipment lifecycle. Repairs and rebuilds can add life to your machines and reduce costs to your bottom line,” Caterpillar said on its website. Keeping track of maintenance can be difficult. Despite having proper maintenance processes in place, human error can still rear its head. Maintenance needs great attention to detail and people can overlook or miss key points. This is where a

preventive maintenance program can help, ie a series of processes, guidelines and tools for conducting regular and routine maintenance on assets to keep them in the best condition possible. An effective preventive maintenance program should consist of an up-todate asset inventory, a schedule of upcoming tasks and procedures, and a record-keeping system where activity can be logged and tracked. All staff members using the relevant assets should undergo preventive maintenance training to help ensure safety. This could include how to manage machinery parts and monitor equipment performance. As technological change evolves, the way mining equipment and machinery runs and operates will change. But companies will always have to commit to upholding the health and safety of their assets and, more importantly, their people.

SAFETOWORK.COM.AU 29 JAN-FEB 2024

Maintenance

The road to zero safety incidents A MULTIFACETED APPROACH TO ITS EQUIPMENT IS HELPING EPIROC ELIMINATE LIVE WORK.

achinery is what keeps the wheels of the mining industry turning, so as every miner knows, maintaining these assets is critical to operational success. But performing maintenance on these enormous machines – which break rock and haul tens of tonnes of material at a time – can be a dangerous affair. This is especially true when it comes to live work, which denotes work conducted within the operating footprint of an energised machine.

That’s why original equipment manufacturer (OEM) Epiroc has spent the last seven years working tirelessly to eliminate live work in the mining and construction industries. “There have, very unfortunately, been a few accidents in the industry involving maintenance on heavy mobile equipment,” Epiroc regional performance centre manager Asia Pacific Paul Lucas told Safe to Work. “Around 2016 there was a fatality during maintenance, and that’s where my journey with live work elimination began. The industry had an epiphany

that people were getting hurt unnecessarily by working on machines that are still running.” The journey towards eliminating live work began with ‘soft controls’, procedural changes to the way maintenance was conducted that removed the operator or maintainer from the machine’s footprint wherever possible. “Back then, we started by rewriting our procedures to facilitate working on zero-energy machines,” Lucas said. “The first phase of any sort of the hierarchy of controls is soft controls. For example, our approach shifted from physically measuring hydraulic pressure while the engine’s running to using a pressure gauge to measure

The ability to work from a remote control room is a key aspect of eliminating live work.

SAFETOWORK.COM.AU 30 JAN-FEB 2024

Epiroc has worked to remove people from a machine’s footprint wherever possible.

“The industry had an epiphany that people were getting hurt unnecessarily by working on machines that are still running.” while the operator stands outside of the machine’s footprint. “Of course, soft controls will only get you so far. We then took the longer-term approach of designing live work out of our machines.” Epiroc performance centre lead engineer Tim Nawrocki said the company’s approach to redesign began with live work mapping and auditing. “In partnership with our R&D (research and development) team in the factory, we looked at where live work activities came up in the operation of our machines,” he said. “We were able identify those instances of live work and then look at ways to eliminate them.

“The next step was to actively partner with our customers to understand their live work activities and their priorities in eliminating them.” One such design evolution is Epiroc’s automatic bit changer (ABC) system for drill rigs, which allows operators to change bits without leaving the cab, or even from a control room. “Previously, a bit change was a fairly high-exposure activity where you needed someone on the drill deck near moving parts to execute that bit change,” Nawrocki said. “Epiroc design engineers in the US developed the ABC system to eliminate that live work.” SAFETOWORK.COM.AU 31 JAN-FEB 2024

Epiroc’s SmartROC D65 MKII drill allows operators to adjust pump pressures from within the cab.

Maintenance

Epiroc’s automatic bit changer (ABC) allows operators to change bits without leaving the cab.

Another redesign example is the SmartROC D65 MKII drill rig. “One key difference between the MKI and the MKII is that the newer model allows you to adjust all your pump pressures within the cab, rather than manually adjusting the pumps on the machine,” Lucas said. “Hydraulic pump adjustment was previously a very manual task. Our rig control system allows the operator to measure and adjust the pressure from within the cab, allowing them to set up the machine for specific operating conditions.” As Nawrocki said, the elimination of live work isn’t always a high-tech affair. Sometimes it means a new component, rather than a new model of machine. “Fluid sampling is typically something that requires the machine to be running, with someone opening a tap to collect the sample,” Nawrocki said. “We worked with a supplier to integrate a sampling system that allows the operator to remotely command a sample to be taken, and

then collect the sample later once the machine is switched off.” In some cases, Epiroc can also retrofit its live work solutions to older models, which means customers don’t always need the latest and greatest equipment to keep workers safe. In fact, the OEM has an entire engineering team devoted to precisely that dynamic. “Epiroc has a multi-tiered approach where we’re looking at delivering new machines with features that eliminate live work, but also trying to reduce the risks on our existing fleet by adapting the same principles and applying them as retrofit kits,” Lucas said. “That way our customers don’t have to buy a new machine to get some of the newer safety features.” Beyond the realm of safety, live work elimination also translates to improved operational efficiency. “If you take away the need to be working on a live machine, you can actually reduce maintenance time as well,” Lucas said.

“So in that way, not only do you improve safety, but you also improve maintenance and maintainability on our machines, which is a win for everybody. “Machines are cheaper to run with less exposure to risk for operators and maintainers.” Though Epiroc is one of the main drivers behind the movement to eliminate live work, Lucas is happy to report that the effort is industry-wide. “There has been a lot of collaboration across OEMs and customers towards the elimination of live work,” he said. “A lot of dialogue and examples are being shared across the industry in this space, because safety is paramount in mining and everybody wants to come home from work. “I think that when it comes to safety, you have got to set aspirations quite high. Epiroc’s goal in the near future is to deliver a machine that requires no live work.”

SAFETOWORK.COM.AU 32 JAN-FEB 2024

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Maintenance

Engineered for success

MASPRO IS HELPING ITS CUSTOMERS OPTIMISE THE PERFORMANCE AND SAFETY OF THEIR MOBILE MINING EQUIPMENT WITH AFTERMARKET SPARE PARTS AND UPGRADES.

lobal original equipment manufacturers (OEMs) produce arsenals of machinery to handle any job under the sun. But relatively few of these machines are specifically designed for the often-harsh conditions seen in Australia. A machine is the sum of its parts, and if one of those parts fails, then the asset becomes a liability. This is the conundrum that MASPRO has been solving for almost two decades. “MASPRO is a manufacturer of after-market spare parts and upgrades for a range of machinery in

underground and surface hard-rock mining,” MASPRO head of engineering Tony Waterman told Safe to Work. “We typically work with exploration, development and production drill rigs. These machines conduct very rigorous work where every little bit of space counts.” MASPRO makes thousands of parts, everything from common service parts to larger components like parts of the boom for a drill. As an Australian company based out of Condobolin in regional New South Wales, everything MASPRO manufactures is

optimised to handle tough Australian conditions. This allows the company to enhance OEM machinery safety, reliability and productivity for Australian mine sites. “Some OEM parts just aren’t up to the task here because of how harsh the environment in Australia is,” Waterman said. “Mine sites are looking to maximise their maintenance intervals, but that’s not possible without parts that last.” Such was the case when a client came to the MASPRO team for help with an issue it was experiencing with its drill rig boom cradles.

MASPRO manufactures after-market spare parts and upgrades for mining industry equipment.

SAFETOWORK.COM.AU 34 JAN-FEB 2024

MASPRO incorporates automation into its manufacturing processes to minimise physical strain for workers.

“The client was having issues with the pin coming loose in an essential component of the rig during operation,” Waterman said. “The operator noticed the boom was rocking during operation, and when they investigated the boom freely fell out. It could have easily ended in a catastrophic failure during operation. “The customer had several incidents owing to this faulty component.” “We came up with a solution and re-engineered the component by including a safety mechanism that triggers in the event of a failure to stop that part of the rig from separating. It also gives the client a visual indicator in the event of a failure.” This addition has incrementally improved the safety of the component. In another case, a client was having issues with the durability of a rotary head for surface hard-rock drilling. “The client was seeing the equipment failing at a very low interval. It was having to be replaced every 600 hours,” Waterman said. “We assessed the part and realised it wasn’t taking certain forces into account. We were able

to redesign the part to last over 6000 hours, in line with the client’s maintenance schedule.” “Everything we offer is designed and made in Australia for Australian conditions. This gives our clients the ability to have reliable maintenance schedules and improve the safety of their machines. That’s the core of our business.” And best practice in safety is not just reserved for MASPRO’s clients, but also its own manufacturing team. “All of our design, fabrication and manufacturing is done onshore with an in-house engineering team who are focused on creating solutions for our customers, always to the highest safety standards,” Waterman said. “We incorporate as much automation as we can into our manufacturing processes to support loading, lifting and carrying, reducing risk of harm and repetitive stress injury for our production teams. “People have families. You want to go home at the end of the day with all your fingers and toes. “We take our safety seriously, that goes for both our team and our clients.”

SAFETOWORK.COM.AU 35 JAN-FEB 2024

Maintenance

Two sides of the same coin MAINTENANCE GOES HAND-IN-HAND WITH INCREASED OPERATOR SAFETY. TAKRAF HAS TAKEN THAT TO A WHOLE NEW LEVEL.

hat is maintenance in the mining industry? Is it the daily checks of a mine’s equipment? Is it the twice-yearly scheduled servicing of the essential technology in the control room? For TAKRAF Group, it’s these things and so much more. “At TAKRAF Group, we believe that the safety and efficiency of maintenance work definitely do not need to ‘cannibalise’ each other and, more than this, with smart solutions will actually complement and enhance each other,” TAKRAF Group chief executive officer Thomas Jabs told Safe to Work. “We believe, as mining statistics worldwide show, that increasing efficiency and improving safety are two sides of the same coin – a safer mine is, in fact, a more productive one.” While traditional thinking may suggest that an increased demand

for safety coupled with the growing complexity of modern mining equipment leads to more complicated maintenance work, TAKRAF has made it its business to prove to the mining industry that this is not the case. “This is highlighted by the TAKRAF X-TREME class sizer,” Jabs said. “The TAKRAF X-TREME class sizer was developed to meet the requirements of the group’s intelligent and holistic maintenance philosophy, which facilitates the achievement of both optimal maintenance safety and efficiency.” In line with this philosophy, the sizer has been engineered to reduce wear, and therefore maintenance, through its durability, abrasion resistance and intake behaviour. It is also designed for a high level of maintenance flexibility to adapt the best concepts appropriate for each individual application. “For example, the sizer provides for maximum flexibility in machine

dismantling, from replacing each tooth (pick) or segment radially in any position to replacing entire rolls or the entire sizer,” Jabs said. “Every component of the X-TREME class sizer has been designed to reduce downtime and ensure that the machine is brought back into production as soon as possible, using our quick-release system. “For example, the bolted tooth system enables worn crushing teeth to be replaced in seconds.” Those seconds can really count on a mine site, so making the most out of every one of them is crucial and the X-TREME class sizer bolted tooth system helps bolster efficiency. “In addition, a tungsten carbide overlay maximises the lifetime of wear parts, such as the crushing teeth, which are subject to high abrasion,” Jabs said. Another example of an ease-ofmaintenance feature in the X-TREME

The TAKRAF X-TREME class sizer.

SAFETOWORK.COM.AU 36 JAN-FEB 2024

The sizer’s split housing design enables the safe and efficient replacement of entire crushing roll assemblies.

class sizer is the quick change-out of crushing segments. This enables the targeted and efficient replacement of individual parts, reducing downtime and making certain that machines get back to production as soon as possible. “The modular wear components of our machine are easy to handle, and change-out procedures can be conducted in position,” Jabs said. “This component helps us to ensure that our machines are brought back into production as soon as possible, even when we are talking about the entire machine itself.” An integrated moving unit allows the entire unit to slide into its maintenance position for safe and quick maintenance. This offers a high level of configurability to develop a maintenance solution that best adapts to plant requirements, ranging from a hot-change arrangement to a checkertype arrangement with various operational slots. The hot-change arrangement with travel sets enables a safe, rapid and efficient ‘hot-swap’ between an operational machine and a spare sizer on the same platform. “Expanding on the hot-change method, TAKRAF also provides a checker-type arrangement for multiple machines in primary, secondary or even tertiary applications,” Jabs said. “This configuration allows several machines to benefit from the efficiency of a single common spare sizer.

The bolted tooth system in the X-TREME class sizers enables the rapid replacement of worn crushing teeth.

An integrated moving unit allows the entire unit to slide into a position for safe and efficient maintenance.

“A checker-type arrangement can be provided in different customised versions for a scalable number of operational sizers and with a fixed crane and/or loading bay being optional. “Both solutions – hot-change and checker arrangement – can feature various devices to lift and move the sizers.” While TAKRAF sizers provide maximised maintenance flexibility by default, the presence of dedicated maintenance areas and spare machines enables crushing operations to continue while maintenance activities are being performed. For most applications, this separation means a safer and more ergonomic maintenance regime with reduced time-pressure, avoiding shortcuts and unsafe practices.

“TAKRAF’s solutions exemplify a commitment to separating equipment in operation from its maintenance,” Jabs said. “This separation leads to increased maintenance safety and heightened productivity. “We firmly believe that improved maintenance solutions should always bring about safety benefits, and that there is no need for safety enhancements to come at the cost of maintenance efficiency. “Even if a solution demands higher initial capital expenditure, it undoubtedly contributes to lower total ownership costs. Such cost savings are realised through improved efficiencies that result in quicker and safer equipment reintegration into operations, ultimately leading to more production time.”

SAFETOWORK.COM.AU 37 JAN-FEB 2024

Maintenance

“Accurate adjustments are essential”

JOHNSON INDUSTRIES, AN EXPERT IN INDUSTRIAL BRAKE SYSTEMS, DISCUSSES HOW IT KEEPS SOME OF THE MOST IMPORTANT EQUIPMENT IN AUSTRALIAN MINING OPERATING SAFELY AND EFFICIENTLY. A Johnson Industries lowspeed conveyor brake.

he mining industry is powered by large and technologically impressive machines, and making sure they’re regularly maintained is essential for safety. But maintenance means downtime, leaving mining companies to walk the line between maximising production and keeping machines running in tip top shape. Safe to Work sat down with Johnson Industries chief executive officer Lawrence Johnson to discuss the maintenance of industrial brakes, and what the company is doing to keep its mining industry customers safe. “Industrial brakes, like any other equipment, require monitoring and periodic adjustment,” Johnson said. “The most important parameter to watch on any properly functioning industrial brake is the air-gap between pads and disc. The air-gap is usually

set during commissioning, but will increase as pads wear. “Maintenance personnel must periodically measure this gap and adjust the pad positioning to reset it. Failure to do so will result in reduced brake torque, and hence poorer performance.” Johnson Industries industrial brakes can be found at most of the major mine sites around Australia in applications like ball mills, semi-autogenous grinding (SAG) mills, conveyor systems, wheel grippers on rail systems, and general crane applications. “We specialise in making custom brakes for larger industrial applications,” Johnson said. “Our goal is to make our brakes as reliable as possible, minimising downtime a mine may experience due to faulty brakes.”

When it comes to maintaining these industrial brakes, quality and consistency go hand-in-hand. Failure to adequately maintain brakes can lead to incidents such as conveyor runaways, which can have catastrophic consequences for assets and worker safety. “Properly functioning brakes are crucial for safe equipment operation, so accurate adjustments are essential. Otherwise, damage and downtime may occur,” Johnson said. “In some cases, inadequately trained personnel conducting these adjustments make mistakes or even neglect the equipment due to fear of making a mistake. “To help train workers and give them the confidence to work on our brakes, we offer written manuals with clear instructions on adjustment procedures.

SAFETOWORK.COM.AU 38 JAN-FEB 2024

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“On request, we can provide maintenance lectures, onsite installation supervision, maintenance personnel training and start-up support. We can also perform inspections, adjustments, and maintenance services for our braking systems.” The intelligent design of Johnson Industries brakes also helps lift some of the load when it comes to maintenance. “Our direct-acting brakes have removable actuators to make shoe and actuator replacement easy, and our lever brakes are highly serviceable, also permitting shoe replacement without removal of the entire brake movement,” Johnson said. “Lastly, in the case of some of our electrically actuated brakes, selfadjusting mechanisms are used to maintain the correct air-gap. “This means the brakes can automatically adjust as the brake pads

wear down. That way, machines can run for longer without losing brake torque.” Johnson Industries has a decades-old presence in the US, as well as an expanding role in the Australian market. Brakes are often

the last line of defence in the event of a mechanical fault, so their upkeep is critical. Johnson Industries is making maintenance more approachable with its premium-quality braking systems and helpful network of experts. Johnson Industries brakes at work on a grinding mill.

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4/12/2023 4:15 pm

Coal fires

A coal comeback AFTER CLOSING DUE TO A FIRE IN 2018, THE NORTH GOONYELLA COAL MINE IN QUEENSLAND IS SET TO REOPEN.

orth Goonyella owner Peabody Energy, a US-based coal company, will spend more than $760 million to bring the Bowen Basin mine back into operation. North Goonyella, an underground metallurgical coal mine located in Queensland’s Bowen Basin region, boasts more than 70 million tonnes of coal reserves. Peabody has also acquired a nearby coal deposit, which is expected to give North Goonyella a life of mine in excess of 25 years.

SUDDEN FIRE

In September 2018, rising methane levels within the North Goonyella underground mine halted operations. Mine officials and safety regulators worked for weeks to stabilise gas levels, but efforts were unsuccessful. The coal seam spontaneously combusted, causing a fire that damaged the mine and caused it to stay shuttered for five years. Coal fires are known to trigger relatively easily and burn intensely, posing a significant challenge for emergency services.

Peabody has been working hard to reopen North Goonyella since 2018.

SAFETOWORK.COM.AU 40 JAN-FEB 2024

“Spontaneous combustion is a well understood phenomenon. Coal … is very reactive to oxygen and will generate carbon dioxide, and that creates heat.”

North Goonyella underground coal mine in Queensland.

In addition to the danger posed by the fire itself, burning coal releases a number of dangerous gases like carbon monoxide, nitrogen dioxide and sulphur dioxide, which poses a significant risk to workers. Fortunately, North Goonyella workers were evacuated from the site in the early days of the incident, before the gas combusted. In a 2014 interview with ABC Science, former director of the Minerals Industry Safety and Health Centre at the University of Queensland, Professor David Cliff, spoke about some of the challenges associated with coal fires. “Unlike timber, coal when it gets hot has massive thermal mass which is very hard to extinguish,” he said. Cliff said coal fires can be triggered both by external sources of heat, such as open flames, as well spontaneous combustion as the coal oxidises. The latter is what happened in the case of North Goonyella. “Spontaneous combustion is a well understood phenomenon,” Cliff said. “Coal … is very reactive to oxygen and will generate carbon dioxide, and that creates heat.

“As the coal gets hotter it will eventually get to flame temperature and that coal will burn.” In an underground environment, mine workers are in a constant battle to reduce gas levels and heat near coal seams to prevent spontaneous combustion. Common controls in underground coal operations include

North Goonyella’s reopening will be a boon to the local economy.

SAFETOWORK.COM.AU 41 JAN-FEB 2024

ventilation, automatic fire warning devices, instruments to measure gas levels, water sprays to reduce dust levels, and physical control measures to prevent potential ignition sources from coming into proximity of the coal seam. Cliff said that with enough coal in one place, a fire can burn for years without relenting. Such is the case at the aptly named Burning Mountain in New South Wales, were a coal seam 30m below the surface has been burning for almost 6000 years, before recorded history began. In addition to how easily a coal fire can start, they are notoriously difficult to extinguish.

Coal fires “The way to put a fire out is to cool it down and exclude the air, but the carbon dioxide and carbon monoxide fumes from such a large fire will be toxic at close range and the heat will be unimaginable, so you can’t get the [firefighters] too close,” Cliff said. “You have to start with massive amounts of water from high-pressure water hoses from a safe distance, and once you can start to bring the temperatures down you can do other things to try to restrict the air access.” In an underground environment such as North Goonyella, these challenges are compounded. In a preliminary investigation into the incident, Resources Safety and Health Queensland (RSHQ) made a number of observations. The regulator indicated that a review of the mine’s records suggested the gas trends were not given sufficient consideration. “Some key reports relating to the mine’s ventilation plan, gas alarm system and explosion risk zone

controls do not appear to have been reviewed or countersigned by key personnel, as required under the mine’s safety and health management system,” RSHQ said. According to the regulator, there was evidence that some boreholes located deep within mined-out regions were insufficiently sealed, allowing ingress of oxygen into active parts of the mine with the potential to escalate conditions for spontaneous combustion. “There is evidence to suggest that the gas drainage system was being operated to focus on management of methane instead of the potential spontaneous heating event that was occurring underground,” RSHQ said. “There is evidence to suggest the mine did not follow its own procedures relating to major ventilation changes.” As part of recent redevelopment works, Peabody has targeted improved ventilation, conveyor systems, infrastructure and more to

safeguard the mine against future gas and fire risks.

REOPENING THE GATES

With the lessons of the 2018 fire taken in stride, Peabody said the North Goonyella will reopen safer and stronger than ever. In late 2023, Queensland Mines Rescue Service (QMRS) entered the damaged mining zone to assess the mine for safety compliance. Following the investigation, QMRS will officially hand over to North Goonyella management. The mine’s reopening is good news for the local economy, with North Goonyella mine expected to support hundreds of jobs. “We’re trying to source as much of the labour, supplies, equipment and manufacturing as we can from the local area,” North Goonyella general manager Dan Proffitt told 7News Mackay. “To us, this is the culmination of four years of hard work to get back to this position.”

Rescue crews conducted safety checks on the mine in late 2023.

SAFETOWORK.COM.AU 42 JAN-FEB 2024

Nivek B

Peabody president of Australian operations Jamie Frankcombe said that although there remains plenty of work ahead, he is pleased to see North Goonyella on track for first production in 2024. “This is a really exciting turning point for Peabody and the team at North Goonyella as we … take a big step in our staged approach to restarting one of the best steelmaking coal mines in the world,” Frankcombe said. “At Peabody, safety is our core value and the safety of our workforce will be the top priority as they work towards bringing the mine up to full production. “I want to thank all the hardworking teams that helped us reach this important milestone, including our employees who have been there for Peabody for over five years since the incident, as well as RSHQ, the community and the industry for their support throughout the process.”

Longwall coal mining at North Goonyella is targeted for 2026.

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23/11/2023 11:03 am

Conveyor safety

Where production and profit meet

MARTIN ENGINEERING EXAMINES THE WAY CONVEYORS ARE SPECIFIED, DESIGNED, PURCHASED, OPERATED AND MAINTAINED.

ngineers have spent decades attempting to design, install and maintain belt conveyor components that eliminate fugitive materials to improve the working environment, reduce accidents and increase productivity. But why? It is estimated that 85 per cent of belt conveyor maintenance and production problems are related to fugitive materials – dust, spillage and carryback. Accordingly, a similar percentage of conveyor safety issues arise from these same materials.

The number of workplace injuries has seen a steep decline over the last century, but we have reached a point of diminishing returns. To achieve the next level of improvement in reducing conveyor accidents, the approach to these complex systems must change, including the way conveyors are specified, designed, purchased, operated and maintained.

increased release of fugitive materials, which in turn result in scenarios that encourage workers to potentially react unsafely: • Production-first culture • Low-bid purchasing • Needlessly complex designs • Over-regulation • Understaffing or undertrained personnel

ROOT CAUSES

Production-first culture When the focus is on production at the cost of all else, it’s little wonder that workers take risks to

It has been found that there are five root causes of workplace injuries and fatalities that lead directly to an

Improving the safe access to and maintenance of conveyors significantly increases efficiency.

SAFETOWORK.COM.AU 44 JAN-FEB 2024

of the customer perception that those benefits ‘cost too much’ and the supplier’s need to ‘win the bid’.

Return on safety cost versus time analysis.

keep conveyors running. Corporate slogans touting workplace safety and environmentalism can become a smokescreen for what the workers really see: production comes before safety. Obviously, the reason a company operates is production. So to counter any hypocrisy, corporations would be better off admitting up front that production is the focus. A better and more realistic goal would be ‘production done safely’. Low-bid purchasing A poor management culture starts in the boardroom, where decisions on capital expenditures are typically based on feasibility studies that only consider direct costs as identified by conventional accounting practices. Historically speaking, purchasing decisions are almost universally based on a ‘low-bid’ process. The details are left to be resolved as operating costs (and often maintenance expenses) and are not thoroughly considered in the engineering or construction phases. In the long run, the cost of buying cheap can get very expensive. A low-bid system often fails to deliver the required production capacity, while also posing greater hazards to workers. In fact, low-bid designs often turn out to be the most costly, because they can generate significant expenses for subsequent

modifications as a result of issues discovered during trials and start-up. The focus should instead be on lowest cost over the life of the system. Needlessly complex designs Complexity does not necessarily improve safety. Simple designs are often harder to realise, but the extra design time required to simplify the operation and maintenance of conveyor components that directly affect production and cleanliness has an enormous payoff. Unfortunately, the same benefits are almost impossible to incorporate in low-bid designs due to the intersection

Over-regulation Industry groups and associations, standards-writing organisations, countries, states and cities have issued thousands of pages of performancebased safety regulations. In many cases, rules within a country contradict each other or are not applicable to the industry in which they are enforced. The effort required for suppliers to comply with so many rules is immense, and these efforts are often negated by the varying opinions of a multitude of inspectors. Conforming to the complicated assortment of regulations and passing opinion-based inspections becomes problematic at best, but it seems clear that countries with specification-based standards have lower fatality rates. Understaffing or undertrained personnel The lack of adequate funding for maintenance is epidemic in the bulk material handling industry. Millions are spent on components, yet these investments are often made without the added maintenance budget needed to keep the components in a sound and safe operating condition.

Performance versus specification-based standards.

SAFETOWORK.COM.AU 45 JAN-FEB 2024

Conveyor safety

Mean time between failures.

Generally speaking, the size of a maintenance crew is based on mean time between failure (MTBF) for major pieces of equipment, based on the questionable conclusion that workers can maintain all minor components of the system in their ‘spare’ time.

work environment were made service-friendly and installed with adequate access, much of the beneficial maintenance could be done safely while the conveyor is in operation.

While most maintenance workers are skilled technicians, they rarely understand the conveyor holistically. Conveyors are complex, integrated systems – a change to one component will often have

PRODUCTION DONE SAFELY

Most equipment is unfortunately not designed for easy inspection or safe maintenance. As a result, maintenance during scheduled production outages of minor components must often be deferred due to access conflicts, lack of time or budgetary constraints. This further reduces components’ functionality, often to the point where they become useless and unrepairable. Conveyors are powerful systems designed to be rugged and durable to deliver near-constant operation, and the belt can be dragged across piles of dirt or inoperative idlers for extended periods of time, as long as the major functions are kept running. If the components critical to maintaining a clean and safe

Enclosed systems with inspection doors protect workers from fugitive material hazards while they check operations.

SAFETOWORK.COM.AU 46 JAN-FEB 2024

unintended consequences for others, affecting the rest of the system. Without a complete understanding of how conveyors are designed and components selected, maintenance becomes an exercise in finding the longestlasting temporary solution to treat the symptoms rather than solving the root causes. Before long, an accumulation of bad choices results in a system that cannot operate at maximum efficiency. Treating symptoms shortens component life – belt life is often sacrificed – resulting in the need for increased spare parts, which in turn increases the need for maintenance labour.

SAFETY PAYS

A major investment in conveyor improvement would rarely be justified on safety alone, and it seems clear that current financial analyses do not include safety in a meaningful way.

Service technicians walk the belt and note changes in performance that may affect safety and increase the cost of operation.

Hierarchy of controls.

We have reached a point where engineering controls, additional regulations and protective equipment are no longer sufficient to continue the trend of improving safety. Instead, we must change the way we address conveyor systems. This change must

include the way conveyor components are specified, designed, purchased, operated and maintained. An in-depth financial analysis shows that additional design time (to address the root causes) and purchasing on the basis of true lifecycle costs (for longevity) will have a high return over time. Increased worker safety is a byproduct of this methodology. With this increase in design time, the altered purchasing habits and the increase in safety are used in the financial justification as inputs, and the return on investment is much higher than with rapid designs and low bid. This mathematical phenomenon is exhibiting itself in reality. A survey of the literature indicates companies that truly focus on safety in the design and practice are more productive and operate cleaner, safer facilities. Conveyor-owning companies must be committed to making those conveyors as safe as possible in order to maximise earnings and value. When combined, an altered way of looking at accidents financially, a change in design methodology, and a change in purchasing methodology will allow a conveyor operator to create a safer environment, increase efficiency and achieve the goal of production done safely.

SAFETOWORK.COM.AU 47 JAN-FEB 2024

Communication

Mission-critical communication SEPURA’S COMMUNICATIONS COMBINE RELIABILITY, ROBUSTNESS AND LONG RANGE TO KEEP MINE SITES CONNECTED. Sepura’s range of VHF TETRA communication products.

hen it comes to the resources sector, being able to communicate effectively and reliably is as critical for operational success as it is for safety. But mine operations in Australia are vast and often remote, which presents a serious challenge when it comes to communications. TETRA (terrestrial trunked radio) is a leading standard in communication established in heavy industries like mining owing to its high standards of service, reliability and security. With its latest range of communication products, Sepura has combined TETRA, a tried-andtrue means of communication, with the extended coverage of VHF (very high frequency).

Consolidating multiple networks into one mission-critical voice, Sepura’s VHF TETRA solution can reliably carry communications across vast outdoor sites and complex underground networks. “Because VHF radio waves work over a much larger distance, this offers considerable advantages to a user organisation,” Sepura product manager Phil Retsas told Safe to Work. “If you’re talking about a site that is 50 square kilometres and you need consistent coverage across that site to ensure safe, efficient operations, then VHF TETRA opens up many new opportunities.” The Sepura SC20 or SC23 TETRA hand-portable radios and the SCG22 mobile radio allow users to implement a complete VHF TETRA solution.

With VHF TETRA, coverage is noticeably better and audio clearer than on legacy radio systems. And with the innovation of global navigation satellite system (GNSS) positioning, team leaders can locate and manage their resources quickly and safely. The TETRA solution also includes emergency response capability. Sepura country manager – Australia/Oceania Ronan Rafferty explained some of the safety benefits of VHF TETRA. “You don’t always have eyes on your workers in mine sites,” he said. “Sepura’s products enable you to ensure you are always in contact with the team, whether deep underground or at the very edges of the mine site. This is a massive factor in enabling safer mining operations.

SAFETOWORK.COM.AU 48 JAN-FEB 2024

up and maintenance costs but also the amount of time needed to roll out a site-wide communication solution like VHF TETRA. When it comes to necessary infrastructure, Sepura’s VHF TETRA solution can be rolled out with the MultiTech Base Station from DAMM Cellular Australia. The VHF TETRA range also grants access to a wide range of communication modes such as SMS and SDS, direct (DMO), trunked (TMO) and gateway operation. It also provides access to feature-rich applications like geo-fencing, auditing and audio optimising functions.

Sepura radios are built to handle the toughest conditions.

“You don’t have to worry that they might unknowingly be going into a blast-zone or somewhere that is unsafe because there is reliable two-way communication.

THE RANGE “We provide for operations where communication is critical, so maximum reliable coverage is our main focus.” Extended coverage also means sites require less communication infrastructure, reducing not only set-

Sepura’s SC20 has been complemented with a streamlined version called the SC23. This new product has a reduced keymat, monochrome display and simplified functionality. It will also be available in VHF bands.

SAFETOWORK.COM.AU 49 JAN-FEB 2024

Communication Sepura’s devices help workers on the ground, in the office and behind the wheel stay connected.

Another key feature of Sepura’s devices is a robust IP68 rating, rendering them impervious to submersion and facilitating easy cleaning under running water. They are ready for immediate operation after they are cleaned, in turn eliminating downtime. So-called ‘water porting’ means water or dust can be expelled from the speakers and microphones with ease. These benefits extend to Sepura’s accessory range, including its Ultra RSM. This speaker microphone has been upgraded to feature an anti-magnetic speaker that repels magnetic dust, prolonging life in iron ore environments. In other words, neither a dust storm nor a downpour can threaten Sepura communications. “Our radios are designed to be durable enough to withstand conditions on mining operations,” Rafferty said. “This includes hazards such as dirt, water, iron ore dust and also heavy treatment such as knocks and bumps – all things that are par for the course in the industry.”

“Sepura’s products enable you to ensure you are always in contact with the team, whether deep underground or at the very edges of the mine site.” All radios in the VHF TETRA line also feature smarter connectivity options such as Bluetooth and Wi-Fi, meaning they can be updated without needing to be physically removed from trucks and other machinery. This allows the wheels of operation to keep turning while communications are being updated.

SEPURA VERSATILITY

Notwithstanding the reliability of TETRA, some operations have high-bandwidth data needs beyond current capabilities. Some sites require data services such as video, access to online tools or databases, and the ability to upload or download large data items. These tasks typically need a higher

bandwidth than narrowband systems like TETRA can deliver, and require broadband data services, such as LTE (long-term evolution). Sepura’s solution to this problem is the hybrid SCU3 TETRA/LTE vehicle device. Designed for use in vehicles and fixed office locations, the hybrid SCU3 combines TETRA for mission-critical voice with highseed data capability through LTE or Wi-Fi connectivity. With its hybrid SCU3 and range of TETRA VHF products, Sepura proves why it is a leading voice in the mining industry. The communications expert has a trick up its sleeve for any situation, helping miners stay safe and connected wherever they are.

SAFETOWORK.COM.AU 50 JAN-FEB 2024

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Storm safety

Preparing for the storm

FROM LIGHTNING STRIKES TO DESTRUCTIVE WINDS, STORM SEASON PRESENTS A VARIETY OF RISKS TO AUSTRALIAN MINING OPERATIONS.

Having the right procedures in place can help keep workers safe during weather events.

hile storms occur in Australia throughout the year, peak storm season typically runs from October to the end of April, creating hazards that need to be managed by mine operators. That’s why Resources Safety and Health Queensland (RSHQ) is warning mining operations to prepare for the season, which poses a number of risks to workers. The regulator commissioned an expert report into hazards associated with using vehicles during lightning conditions. It identified a number of high-risk incidents with a substantial increase in likelihood of occurrence.

Workers risk exposure to high voltage while standing outside of a vehicle. This includes touch potential, where a worker touches an electrified object; step potential, where a worker is standing on ground that carries electrical current; and side flash, which can occur if lighting strikes a vehicle when a worker is in close proximity. Workers who remain in open areas during lightning storms are exposed to multiple risks, including being directly struck by lightning. Another high-risk hazard comes from vehicles. When struck by lightning, pyrolysis (chemical degradation) can cause vehicle tyres to explode, which can occur in tyres inflated with air and nitrogen alike.

Such an incident occurred on a Queensland mine as recently as December 2022, when three tyres exploded on a dump truck after the vehicle was struck by lightning. The explosion launched tyre fragments and a rock ejector roughly 10m away from the machine. Fortunately, operations had halted during the storm and no one was injured. A lightning strike can also damage the sealing on tyres, presenting a risk of a delayed explosion. RSHQ also identified a number of moderate risks associated with storms. A worker runs the risk of electrocution through ultra-high frequency wiring or other conducting surfaces while inside a vehicle.

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Similarly, the risk of electrocution can come from a direct strict to the vehicle or side flash. According to RSHQ, the safest way to eliminate hazards associated with storms is to cease activities when lightning is detected within close proximity to a work site. The regulator also recommended that vehicles be driven to a designated safe lay-down area, operators of vehicles be transported to a safe shelter away from the equipment, and workers not return to work until an ‘all clear’ has been given. Beyond the risks posed by lightning, severe winds can also present a safety hazard for mine sites. RSHQ chief operating officer Rob Djukic said there have been issues in previous years with fabric building structures like igloos that aren’t capable of withstanding heavy weather. “They should never be considered a place of safety during severe weather events,” Djukic said. “Those structures need regular maintenance, but don’t just stop there. Make sure you’re assessing all site facilities deemed to be places of safety during severe weather events.” Such was the case at BHP’s Peak Downs mine when a storm tore through Queensland’s Bowen Basin in late 2020. Several site buildings

were destroyed, including a large maintenance workshop. Fortunately, no one was injured. However, there is precedent for storms claiming lives on Australian mine sites. In 2007, two workers lost their lives at a Western Australia mine when their dongas failed to hold up against category four Cyclone George. More recently, the Department of Energy, Mines, Industry Regulation and Safety in WA put strict rules in place for managing the risks of extreme weather events, including cyclones. Cyclones can isolate workers by cutting off access to emergency services, roads, transport, power, infrastructure and communications. Mine sites must develop emergency procedures and plans in conjunction with local emergency authorities, including preparation, evacuation, and communication protocols. All transportable buildings on-site, such as dongas and offices, must also be adequately secured. According to the WA regulator, essential personnel who remain on-site during a cyclone should be moved to an appropriate designated shelter well in advance of the arrival of the cyclone. Adequate food, drinking water, medical supplies and other crucial items are to be available for all isolated workers.

Critically, all mine workers must be trained in this area to ensure they know what actions to take in the event of a cyclone or other sever weather event. Australia’s most recent storm season also saw record rainfall hit north Queensland, closing several mines in the area. The Capricorn copper mine, owned by 29 Metals, was particularly hard hit by flooding and is not expected to be fully operational until partway through 2024. Danger can come from many places during a storm, but with the right preparation and processes in place, the risks to mining operations can be appropriately managed.

Operating in or around vehicles during a lightning storm is hazardous.

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Lightning can be a particular hazard on a mine site.

Hoists

At the forefront of hoist safety

WITH ITS SIL 3 CERTIFIED MINE HOISTING SOLUTIONS, ABB SHOWS WHY IT’S BEEN A MARKET LEADER FOR 130 YEARS.

oists perform a range of critical functions in a mining operation, playing an essential role in the repair and maintenance of plant and mobile assets. Simply put, hoists lift what people cannot, which makes them potentially hazardous to operators. For that reason, mining companies want a trusted name in hoists, and few are more respected than ABB.

A TRUSTED NAME

More than 130 years of experience has refined ABB’s approach to mine hoist technology. It is the only original equipment manufacturer (OEM)

delivering complete systems based on customised designs for electrical products and mechanical equipment. ABB provides low lifecycle cost solutions with high reliability and system availability. Customers can expect short project execution time and a single source of supply for the complete system, including service and spare parts. Over its lifespan, ABB has delivered more than 1000 hoisting solutions around the globe.

ELEVATING SAFETY

With well over a century in the industry, ABB has helped to drive the evolution of hoist safety to what it is today.

Engineering manager Johan Engelbrecht and engineering intern Aime Parker in front of Mount Isa Mines’ X41 hoist.

An ABB hoist installed at Majialiang mine in China.

ABB technical product manager for its Safety Plus for hoists portfolio Alonso Morey discussed the development of hoist safety in the mining industry. “ABB has been a global leader in the development of mechanical and electrical equipment for hoists for 130 years. We have been always at the forefront of hoist safety,” Morey told Safe to Work. “Hoists are complex machines. Historically, hoist safety meant having an independent system monitoring the movement, speed and position of the hoist. “This included high reliance on the skill of the operators for other manually-controlled protective functions, such as not starting the hoist if a gate is open. These systems would then be able to activate emergency braking if necessary.” Hoist safety, according to Morey, really began to evolve with the idea of functional safety standards – an objective, quantitative measure of safety. Unlike subjective measures and manual inputs from an operator, functional safety standards include expanded automatic responses from the machine itself. Automatic prevention of cage movement while the doors are open is one application of functional safety. In 2005, Australia became the first country in the world to mandate functional safety standards for hoists, defining what protections a hoist required and with which safety integrity level (SIL).

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“Soon after, the IEC [International Electrotechnical Commission] standard 62061 was released, which provides requirements to manufacturers of machines for the integration of functional safety standards,” Morey said. “This is now standard in Australia. “Since then, the Australian guidelines were updated in the Technical Reference Guide for Powered Winding Systems by the New South Wales Resource Regulator in 2020. “Regulations became more specific about the different safety functions necessary for different types of hoists and applications.

FUNCTIONAL SAFETY AT HEART When it comes to regulations, “Australia led the way for functional safety”, according to Morey. “That of course led customers and end users to adopt a view that functional safety for hoisting is the

Shaft sinking at Glencore’s Ernest Henry operation.

right way to go,” he said. “ABB has always been known for its safe hoisting systems, so with the shift to the more objective functional safety principles we redesigned our systems to meet and exceed the latest standards. “These are built into the machines, automatically detecting danger and engaging safety mechanisms. That way risk is transferred from the operator to the automated control system.” Hoist safety has had a long history in Australia but has reached its zenith with ABB’s Safety Plus for hoists, the first SIL 3 (Safety Integrity Level) certified suite of solutions for hoists. A SIL measures the probability of failure of functional safety features on demand. There are four levels of SIL, up to SIL 4 (SIL 3 for machinery). As the rating increases, the higher the safety level of the machine and the lower the probability of failure. ABB goes one step further, having its Safety Plus products independently SIL 3 certified by the Research Institutes of Sweden. The Safety Plus suite is composed of three solutions: the hoist monitor, the brake system, and the hoist protector. These have been rigorously examined and certified, and strictly developed in accordance with the ‘safety of machinery’ standard IEC62061. The Safety Plus hoist monitor comes fitted as standard to new ABB

hoists but can also be easily retrofitted to existing mine hoists, sending a command to apply safety brakes and remove motor torque in the event of a position, speed or movement-related safety hazard. The hoist monitor can detect a vast range of hazards, including critical overspeed, overwind/underwind, encoder drive failure, protection bypass, worn friction linings, rope slip, rope miscoiling, slack rope, unclutched drum movement, roll-back and incorrect direction. The Safety Plus brake system can guarantee SIL 3 protection functions such as: • bringing the hoist to a safe state after a safety circuit trip • holding the hoist unbalance when stopped • preventing unexpected brake release when mine personnel are embarking or disembarking the cage • holding the unclutched drum unbalance • controlling hazardous energy during maintenance • lowering the hoist unbalance under gravity force in case of extended power outage or failure of the drive system. The Safety Plus hoist protector extends safety functions beyond the mine hoist itself to the rest of the hoist infrastructure. The hoist protector is capable of monitoring maintenance lock-outs and emergency stops in areas such as the hoist house, headframe and shaft locations, as well as shaft access level gates, boarding and maintenance platforms, and tail rope wander. These solutions come together with ABB’s long history in the mining industry, as well as its vast network of international experts, to create a titan of mine hoisting safety. “Independent SIL 3 certification means that you don’t have to take my word that we take safety very seriously,” Morey said. “We are proud to offer hoisting solutions that are safer than what most applications would require.”

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Training

Resources Safety and Health Queensland is helping mine and quarry workers safeguard their operations.

Learning from disasters TO FOSTER A TRUE ZERO-HARM WORKPLACE, EMPLOYERS NEED TO RELY ON A TRIED-AND-TRUE METHOD: LEARNING FROM MISTAKES.

he grand scale and complexity of mining operations means risk is ever-present. Unfortunately, that risk can sometimes materialise with harmful – and even fatal – consequences, but buried in every crisis is a valuable lesson for the future. Resources Safety and Health Queensland (RSHQ) chief inspector of coal mines Jacques le Roux told Safe to Work it’s critical that the industry learns from past events. “By studying past incidents and their underlying causes, individuals can better understand the root factors that contribute to safety lapses in mining operations,” he said. “This awareness can serve as a foundation for implementing proactive

measures to prevent future accidents and improve overall safety standards.” To make mistakes is human, and while it can be difficult to genuinely own up to and learn from them, doing so on a mine site can be the difference between life and death. Even the largest corporations aren’t immune from making mistakes. After a fatal accident at its Ahafo mill expansion project in Ghana, Newmont saw the benefits of speaking up. “After the catastrophic accident on April 7 2018 … took the lives of six colleagues, we recognised the need to have open and honest conversations with personnel across the globe on why the accident happened,” Newmont said in its case study about

the accident. “Following an in-depth investigation into the root causes, sites and office locations across our business held sessions on the accident’s critical learnings. More than 9500 employees and contractors participated in the sessions, which encouraged everyone to speak up, ask questions and provide feedback.” The Newmont team came away from these sessions with three key lessons: • Always identify, establish and enforce barricades and exclusion zones where there is a risk of personnel being struck by falling objects • Where we rely on temporary structures in high-risk work activities, these must be designed

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and verified as effective at all stages of the work • When a task does not go as expected or changes occur, take time to establish what has changed and why – assess the risk and seek additional expertise, applying controls if needed, before recommencing the work And the outcome of these lessons? “Each site identified priority actions and developed plans to address the actions and their effectiveness,” Newmont said. “We began to develop global standards for barricading and exclusion zones to support regional standard operating procedures. “We also identified additional critical controls associated with our top fatality risks that must be in place every time a task involving the risk is undertaken.” It’s clear that taking the time to reflect on the accident and develop solutions to ensure it doesn’t happen again is an effective approach. It’s for this reason that Queensland mining operators must report serious accidents and highpotential incidents to RSHQ. From there, the wider industry has a chance to learn from the incident. “It is important that we share information about incidents and investigations to raise awareness of risks and provide information about the events leading up to an incident and recommendations of what can be done reduce the likelihood of similar events,” RHSQ chief inspector of mineral mines and quarries Hermann Fasching said in the MMQ report for the first quarter of the 2024–25 financial year. “RSHQ will continue to publish incident findings through summary investigation reports.” Learning from mistakes is the ethos behind RHSQ’s new training course, ‘Learning from Disasters’. The course is a mandatory requirement for statutory ticketholders at Queensland mines and quarries as part of their ongoing professional development in the Practising Certificate Scheme.

But it’s important to note the content is relevant to many stakeholders across the industry. “While ‘Learning from Disasters’ was developed for statutory ticketholders, it can also benefit emerging leaders and those in supervisory positions who want to contribute towards building a safer workplace,” le Roux said. ‘Learning from Disasters’ also delves into the similarities, differences and overlapping areas between process safety and personal safety. It examines historical accident scenarios from various industries to provide insight into the complexities of managing industrial risks. “Disaster training requires extending beyond coal mines to encompass metalliferous and quarrying sectors, as well as other industries,” Fasching said. “This initiative reflects a proactive and holistic approach to safety and disaster preparedness.” Learners will identify the tangible behaviours, organisational systems and social patterns that underpin a positive safety culture. As a feature, the element ‘reporting culture’ will be discussed to identify how good reporting behaviour impacts safety culture.

The course unpacks good reporting practices and legislative requirements surrounding serious accidents and high-potential incidents. Participants will be provided with a more thorough understanding of their legislative reporting obligations. The course also covers the importance of a ‘just culture’, where workers are encouraged to speak up and report hazards without fear of retribution. This approach is in line with the recommendations of the 2019 Brady Review, which was commissioned by the Queensland Government and looked at all fatal accidents on the state’s mines and quarries from 2000–19. The review emphasised the need for a culture of safety and accountability across the resources industry. ‘Learning from Disasters’ is RSHQ’s latest initiative towards the goal of zero serious harm in Queensland’s recourses industry. But it’s not just Queensland that will benefit from these initiatives. In order to foster zero harm throughout the whole Australian mining industry, each operation must take on board the lessons learnt from any mistakes that are made, lest that accident occur again.

Risks on a mine site can come from seemingly unlikely places.

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Events CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@SAFETOWORK.COM.AU

INTERNATIONAL MINE HEALTH AND SAFETY CONFERENCE PERTH | APRIL 15–17

WOMEN IN INDUSTRY AWARDS 2024

A new-look International Mine Health and Safety Conference is coming to Perth in April 2024. AusIMM’s biennial conference (formally known as MineSafe) will be a gathering of industry professionals, researchers, policy-makers and stakeholders from across the world. The conference will serve as a platform to discuss the latest developments, best practices and innovative solutions in the field of mine health and safety. It will feature industry-leading keynote speakers, thought-provoking panel discussions, interactive Q&As and a suite of technical presentations with the objective of promoting a safe and healthy work environment across all mining operations. • ausimm.com/conferences-and-events/ mine-health-and-safety/

The Women in Industry awards are an opportunity to celebrate the success of women who work in the mining industry. The awards night, to be held in Sydney on June 20, features multiple categories that showcase exceptional examples of industry advocacy, mentorship and broad sector excellence. The Women in Industry Awards recognise outstanding women from across a range of industrials sectors; for example, those who work in mining, transport, manufacturing, engineering, logistics, bulk handling, waste management, rail and construction and infrastructure – all sectors that are traditionally male-dominated. This is an opportunity to recognise the women who are driving change in industry and, in doing so, are breaking down barriers and creating new possibilities for the next generation. • womeninindustry.com.au

MOLTEN 2024

QME 2024

IMARC 2024

BRISBANE | JUNE 17–19

MACKAY | JULY 23–25

SYDNEY | OCTOBER 29–31

A quadrennial conference that has been around for over 40 years, Molten 2024 will be held in Brisbane from June 17–19. What sets this conference apart is its scientific focus and support of the transition to sustainable technologies. The majority of metals undergo some form of high-temperature processing, whether in production, refining or recycling. It is the aim of this conference to make a positive contribution to the exchange and dissemination of knowledge on this important class of processing systems, and thereby enhance the rate of progress to more sustainable industrial processing systems. • ausimm.com/conferences-and-events/ molten-conferences-2024/

The Queensland Mining & Engineering Exhibition (QME) connects leading suppliers and technical experts with those seeking better efficiency and productivity, and increased optimisation for their business. QME 2024 will feature over 250 suppliers on the exhibition floor. A free seminar series provides the opportunity to hear from professionals who will address the current needs of the industry. With live demonstrations and topical presentations, QME will be the ultimate destination for the Queensland mining industry. It is a key place for people to come together to be inspired, innovate and connect. In such a dynamic industry, QME has maintained its importance within the mining sector. • queenslandminingexpo.com.au

The International Mining and Resources Conference (IMARC) is where people from across the entire industry come together to deliver ideas and inspiration. Learn from in excess of 500 mining leaders and resource experts throughout seven concurrent conferences with a program covering the entire mining value chain. Attend one of the many networking events or catch up with industry colleagues on the exhibition show floor featuring more than 470 leading companies. There will be practically endless opportunities to network, brainstorm and share knowledge over the three days at the ICC Sydney.. • imarcglobal.com

SYDNEY | JUNE 20

PNG INDUSTRIAL & MINING RESOURCES EXHIBITION AND CONFERENCE PORT MORESBY, PNG | JULY 3–4 The 2024 PNG Industrial & Mining Resources Exhibition will showcase more than 100 local, national and international manufacturers and suppliers with the latest innovations in the supply of services and equipment for the industrial, mining and oil and gas sectors. The exhibition is the premier meeting place to connect with thousands of decision-makers across a broad industry reach, including senior management, procurement, government personnel, engineers, contractors and trade technicians. With extensive support from key stakeholders in government, associations and industry, PNG2024 is a top-level meeting place for industry and a forum for establishing high-quality customer contacts and conducting business. • pngexpo.com

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Evolving Safety, Consistent Quality. Trust Johnson Brakes. Over a century of engineering excellence. Johnson �ndustries �td., an �SO �� certified company, o�ers the most comprehensive range of industrial brakes, brake systems and rail clamps available from any single source worldwide. Our products are designed and manufactured in-house, including heavy-duty hydraulic, pneumatic, electric, spring-set, manually applied industrial brakes and brake systems, available with a variety of options including automatic lining wear adjustment. Johnson products are utilised in every mining application, including conveyors, stacker-reclaimers, hoists, and SAG mills.

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SAFETY RELIABILITY PRODUCTIVITY

maspro.com.au

SAFETOWORK.COM.AU

2024 | JAN-FEB | ISSUE 29

MASPRO leads the way in creating cutting-edge engineering solutions for underground and surface operations in hard rock mining industry. What sets MASPRO apart is our unwavering commitment to optimising the parts we produce to increase safety and reliability. Our team partners with our customers to ensure that their machinery performs at its peak, even in the harshest mining conditions. Do you want to drill deeper, move more ore, and push your equipment to the limits while maintaining the highest standards of safety and operational reliability? Talk to the MASPRO team today!