25th annual Mechanical Engineering Safety Seminar 2015

1. Mechanical Engineering
Updated
MESS 2015
“Evolution of mechanical safety – 25 years and
beyond”
Peter Sunol, Senior Inspector of Mechanical Engineering

2. The mechanical team
South
– Bob Madeley
– Graham Johnston
 North
– Paul Drain
– Bob Williams
– Dave Clarence
 West
– John Parolin
– Jeff Glasson
 Petroleum
– Sarfraz Hassan
 Technical Services
– Keith Johnson
– Perry Sparks
– Jeremy U’Brien
 Special Projects
– Gavin Black
– Gordon Jervis
– Wally Koppe
 Support
– Dominic Posavec

3. Recognition of previous members
of the mechanical team
 Leo Roberts
 Roger Hoerndlein
 John Bout
 Ray Smith (late)
MESS Organisers
 Steve Stewart
 Julie Downie
 Peter Torr
 Alwyn Russell
 Bob Johnson
 Matt Willoughby

4. Our mines - NSW
Mine Type Underground
Open
Cut
Surface (other)
pit, processing,
dredge, exploration
Total
Coal 31 34 127 202 (-1)
Metalliferous 38 29 395 462 (-38)
Extractives 1 825 1,889 2,715 (+124)
Other 24 8 292 324 (+29)
Petroleum 0 0 266 266 (-14)
Total 94 (+15) 896 (+29) 2,979 (+59) 3,969 (+110)

5. “Evolution of mechanical safety – 25
years and beyond”

6. The incident triangle for 2014/15
2 fatal incidents (-3)
2,097 reported incidents (+471)
??
unreported
near misses
51 serious bodily injuries (+22)
All incidents notified to NSW DTI Mine Safety for 2014/15

7. Serious bodily injuries – all incidents
coal, metal, quarries excluding petroleum
 32 fractures (+11)
 7 amputations (+4)
 1 injection of fluid (+1)
 1 burns
 10 other
Outcomes of injuries
 71 hospital in patients (+16)
 207 injuries of greater than 7 days lost time (-80)
 7 lost consciousness (+6)

8. All Incidents by Sector
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Unknown 2 2 4 4 4 2 5 3 - 4 4
Petroleum (Onshore) - - 3 - 5 14 8 2 2 3 4
Non-Coal Other 1 3 1 2 2 4 2 1 2 6 3
Extractives 78 62 70 62 73 78 107 102 96 120 143
Metalliferous 152 161 151 132 147 186 165 203 226 214 217
Coal 266 339 1,283 2,249 2,569 2,742 2,767 2,625 2,618 2,293 1,803
Total 499 567 1,512 2,449 2,800 3,026 3,054 2,936 2,944 2,640 2,174
499
567
1,512
2,449
2,800
3,026 3,054
2,936 2,944
2,640
2,174
-
500
1,000
1,500
2,000
2,500
3,000
3,500
NumberofIncidents

9. 499
567
1,512
2,449
2,800
3,026 3,054
2,936 2,944
2,640
2,174
-
500
1,000
1,500
2,000
2,500
3,000
3,500
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
NumberofIncidents
Financial Year
Dust
Water
Self Heating
Hazardous Materials
Structural Failure
Other
Strata/Ground Control
Explosives
Mech Equip Fixed
Electrical Energy
Work Environment
Gas
Mech Equip Mobile
All Incidents by Event Subtype
1803
coal

10. Coal Assessments by Event Subtype
678
954
833 815
847
948
830
708
857
985
1,322
-
200
400
600
800
1,000
1,200
1,400
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
CoalAssessments
Financial Year
Closure
Seminar/Workshop
Resource Recovery (Safety)
Hazard/Risk Profile
Airborne Dust
Equipment
Incident Follow-up
Investigation
Management Plans (Safety)
Audit
Explosion Suppression
Inspection (Mine Safety)
355
mechanical
all mine
types 14/15

11. Notifiable Incidents by Category
375
310
287
215
151
106 105
89 89 81
54
45 37 30 25 22 22 18 15 13 8 4 3 3 3 2 2 2 1
0
50
100
150
200
250
300
350
400
450
NumberofNotifiableIncidents
Incident Category
Petroleum
Non-Coal Othe
Metalliferous
Extractives
Coal

12. Number of Notifiable Mechanical Incidents
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Mech Equip Fixed 18 22 43 54 156 160 133 166 138 154 109
Mech Equip Mobile 129 179 594 962 1,074 1,242 1,085 1,070 1,062 970 715
Total 147 201 637 1,016 1,230 1,402 1,218 1,236 1,200 1,124 824
147
201
637
1,016
1,230
1,402
1,218 1,236
1,200
1,124
824
0
200
400
600
800
1000
1200
1400
1600
NumberofNotifiableMechanicalIncidents
Financial Year

13. Number of Notifiable Underground Mechanical
Incidents by Category and Mine Type
124
120
85
25 23 22 19
15 12
8 6 6 3 1 1 1 1
0
20
40
60
80
100
120
140
NumberofNotifiableUndergroundMechanicalIncidents
Incident Category 2014-15
Metalliferous
Coal

14. Number of Notifiable Surface Mechanical
Incidents by Category and Mine Type
92
71
53
44 43
10 10 10 10
3 2 2 1 1
0
10
20
30
40
50
60
70
80
90
100
NumberofNotifiableSurfaceMechanicalIncidents
Incident Category 2014-15
Petroleum
Metalliferous
Extractives
Coal

15. Number of Escape of Pressurised
Fluid/Substance Incidents
361
290
214
192 196
216
184
151
0
50
100
150
200
250
300
350
400
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
NumberofEscapeofPressurisedFluid/SubstanceIncidents
Financial Year

16. What to look forward to next year
 Work Health and Safety (Mines) Regulation
– Licensing / registrations
 A focus on
– ExDES
– Mobile plant fires
– Escapes of fluid under pressure – ancillary form
 Adequacy of risk control
 Functional safety training
 Improvements in information to industry

17. What else
 MDGs, 15, 41 (Comment period closes 31 October)
 MECP, Winder code
 MDG 3, MDG 29, MDG 33 Series
Other MDGs
 Single exams & 2 orals per year
 Ist female manager of mechanical engineering in NSW
 Tom Klinge – Awarded Tire Industry Association of
America “Hall of Fame”
 25 Years of MESS

18. The message
Focus on
 Understanding hazards
 Require control effectiveness
 Control failure modes
 Actual effectiveness
 Monitoring
Don’t
 Focus on document size
 Focus on hundreds of
SWPs
 Prohibit people thinking
 Fill in reams of paper
 Demonstrate actions through engineering rigor
 Keep MECP simple, it is not a control
 Don’t be afraid to ask your mechanical inspector

19. If All Else Fails Remember !!