Electrical engineering safety - back to basics

1. Electrical Engineering Safety
Back to basics
Owen Barry – Principal Inspector of Electrical Engineering
November 2018

2. Electrical Inspectors

3. 3
Electrical Inspectors
Owen Barry Jason Goldie Mark Smith Greg Eaton Craig Harris
Luke MinnisRussell WoodGraeme BrownPhil MortonSteve Bentham

4. Industry performance

5. 5
Raw coal production
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
No. of Mines 52 55 58 60 60 60 62 61 61 55 51 51 47 47 47
Underground 49.3 51.9 52.2 57.2 61.3 63.1 62.8 62.2 60.5 69 74.3 77.5 66.2 60.3 48.9
O/Cut 97.7 104.4 108.9 113.1 115.9 118.9 126 142.7 160.5 176.8 186.5 174.9 180.1 189.6 187.4
Total 147 156.3 161.1 170.3 177.2 182 188.8 204.9 221 245.8 260.8 252.4 246.3 249.9 236.3
0
50
100
150
200
250
300
Tonnes(000,000)

6. 6
Metals production
2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
Copper (tonnes) 146,000 158,000 155,000 158,000 172,000 178,777 204,508 217,386 202,309 188,084 177,562
Gold (kilograms) 34,000 28,000 28,000 30,000 28,000 29,180 33,096 35,444 37,264 35,871 35,382
Rutile (tonnes) 63,000 80,000 69,000 80,000 50,000 97,219 112,620 86,966 87,474 70,661 79,062
Zircon (tonnes) 48,000 56,000 53,000 70,000 86,000 102,401 116,590 96,761 97,071 78,268 106,536
Silver (kilograms) 77,000 71,000 82,000 73,000 81,000 160,779 111,479 108,119 127,894 92,805 102,905
Lead (tonnes) 75,000 73,000 77,000 77,000 78,000 125,910 92,825 98,567 111,623 78,623 108,532
Zinc (tonnes) 140,000 122,000 102,000 102,000 121,000 258,922 199,971 176,390 219,869 165,690 233,821
0
50,000
100,000
150,000
200,000
250,000
300,000

7. 7
Electrical incidents
1999‐
00
2000‐
01
2001‐
02
2002‐
03
2003‐
04
2004‐
05
2005‐
06
2006‐
07
2007‐
08
2008‐
09
2009‐
10
2010‐
11
2011‐
12
2012‐
13
2013‐
14
2014‐
15
2015‐
16
2016‐
17
2017‐
18
Coal 36 70 111 84 91 116 166 200 187 212 241 231 235 325 334 334 301 205 241
Metals 17 27 27 28 26 31 23 27 22 17 23 21 32 39 31 26 22 16 15
Extractives 2 4 2 15 12 10 7 8 8 10 13 8 8 5 10 13 13 0 11
0
50
100
150
200
250
300
350
400
No. of incidents
WHSMR14
1/2/2015

8. 8
Electrical incidents – coal – Ex failures & cable arcs
2007-
08
2008-
09
2009-
10
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
2015-
16
2016-
17
2017-
18
Failure of Ex 62 85 66 66 91 145 173 174 133 109 99
Evidence of arcing on cables 59 60 59 57 58 61 70 49 48 34 35
0
20
40
60
80
100
120
140
160
180
200
NoofIncidents

9. 9
Electrical incidents – coal – other
2007-
08
2008-
09
2009-
10
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
2015-
16
2016-
17
2017-
18
Electric shock 29 25 33 30 40 32 30 25 14 22 14
Unintended activation 18 12 26 23 10 32 30 30 19 16 20
Contact with energise high voltage 8 8 13 12 8 21 13 9 16 9 9
Uncontrolled explosion or fire 3 5 9 9 11 15 10 16 37 15 16
0
5
10
15
20
25
30
35
40
45
NoofEvents
WHSMR14
1/2/2015

10. 10
Electrical incidents - metaliferous
2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
Uncontrolled explosion or fire 2 4 7 3 12 10 8 9 4 4
Electric shock 4 11 10 19 25 19 11 7 10 5
Contact with energised high voltage source 3 2 2 3 1 0 1 3 0 3
Unintended activation of plant 0 0 0 0 0 0 0 1 2 1
0
5
10
15
20
25
30
Noofincidents

11. Back to basics

12. • New technologies require different controls
o VSDs – screened cables
o Larger vehicles – driver assist controls
o Autonomous vehicles
• Rules of thumb do not always apply
o Implicit assumptions – Sean Brady
• Engineering analysis
o Risk assessments with clear safety objectives
12
Electrical Engineering Safety – Back to Basics

13. • injury to persons caused by direct or indirect contact with electricity,
• injury to persons caused by working on electrical plant or electrical
installations,
• the unintended initiation of gas or dust explosions,
• the unintended operation of plant,
• the occurrence of uncontrolled fires
13
Objectives of electrical engineering safety

14. • Crucial to identifying the risks that may be present during an activity or task
o If a risk is not identified, then controls to manage the risk will not be identified
o Involvement of appropriate persons
– OEMs, engineers, tradespeople
• A risk must be eliminated if reasonably practicable
o Otherwise it must be controlled
• Each risk to be assessed in its own right
o As it affects the activity to be undertaken.
• Minimising a risk does not mean reaching a predetermined target level
• Apply the hierarchy of controls
14
Risk assessments

15. • Sets out the arrangements for managing risks in accordance with clause 9
(WHSMPS regs)
o Systems, procedures, plans and other control measures that will be used to
control risks to health and safety
– Developed by individuals with duties and functions
– Specific to that mine
– Address all legislative requirements
o Requires appropriate consultation with workers affected by the risk (Part 5 Div 2
WHS act)
• All work undertaken in accordance with the safety management system for the
mine
15
Safety management system

16. A control that is crucial to
preventing the event or
mitigating the consequences of
the event.
The absence or failure of a
critical control would
significantly increase the risk
despite the existence of the
other controls.
In addition, a control that
prevents more than one
unwanted event or mitigates
more than one consequence is
normally classified as critical.
16
Critical controls

17. COMMON CHALLENGES
Ahead of regulation?
The CCM approach consists of concepts and actions that may be
unfamiliar to regulators in some jurisdictions. This may require companies
or sites to justify and explain CCM to regulators.
17
ICMM Critical Control Management Implementation Guide

18. • Management plans
o Identify how a hazard should be managed
• Training
o Helps to make people knowledgeable in respect of a particular matter
– Knowledgable in the risks posed by a hazard
– Knowledgable in requirements for correct function of a control
• Inspections
o Checks on whether a control is implemented and functioning as intended
• Maintenance
o Aims to keep the control functioning as intended
18
What are not controls

19. • Looking at the safety management systems
o How have critical controls been identified
o How well have they been implemented
– Commissioning
– Inspections
– Maintenance
o Who is responsible for the control
19
Resources Regulator inspections

20. Competency

21. Applicants
2017 2017 2018 2018
1st
round 2nd
round 1st
round 2nd
round
Sat written
exam
No written exam
held
11
8 UG
No written exam
held
12
8 UG
3 OC 4 OC
Passed written
exam
7
4 UG
6
3 UG
3 OC 3 OC
Sat oral exam 2
2 UG
9
6 UG
8
6 UG
7
4 UG
Nil OC 3 OC 2 OC 3 OC
Deemed
competent
Nil
Nil UG
1
Nil UG
4
4 UG
2
1 UG
Nil OC 1 OC Nil OC 1 OC
21
Competency Exams

22. • All Electrical Engineering managers (UG Coal) must have one now
• Electrical engineers (other than UG Coal) have to the 28 February 2019
22
Practicing Certificates

23. 2016 – In closing
• If we continue to do things the way we have always done, then at best
we must expect to get the same results that we have previously
obtained
• Insanity: doing the same thing over and over again and expecting
different results
• We need to change the way we manage risk if we are to have a
significant reduction in the number of incidents that occur
2017 – In closing
• Mine Safety approach to how we regulate is changing
– More proactive assessments
23
In closing – Revision

24. The Resource Regulator approach to regulation is
continuing to change
24
In closing

25. Thank you