HAZARDAVERT BY ILIPS Patents: 7,420,471; 5,939,986; 6,810,353;SA2007/2919 Patents Pending
COLLISION AVOIDANCE SYSTEM PRESENTATION TO SACMA 20 MAY 2010 PRESENTERS: MIKE ELLIOTT SHANE THOMPSON RONALD VENTER
CONTENTS ACCIDENTS HISTORY DESIGN CONCEPTS SASOL EXPERIENCE MANAGEMENT CONSIDERATIONS SYSTEM SAFETY FEATURES SURFACE MINES AND SURFACE PLANTS CONCLUSIONS
ACCIDENTS Rock Falls have been replaced by accidents involving Moving Machines as the highest in number and most severe in injury status Collision Trapped by Caught between Wrong position Fatigue Loss of concentration Poor procedures Lack of training ELIMINATE> MINIMISE> PROTECT
HISTORY NIOSH began work on proximity i detection technology in 1992. MSHA and NIOSH began cooperation in 2002 to address the large number of fatalities occurring around continuous mining machines. MSHA Enforcement Body NIOSH Research Body
30 Remote Control Victims 1984-August 2008 USA Mines Circles - fatality using remote Gray - fatality doing maintenance Gray fatality doing maintenance Squares - fatality not the operator
DESIGN CONCEPTS Low frequency system must not propagate and must not multi-path. th System; minimally affected by metal, rock, dust, debris, water sprays, electrical l currents,etc. t Stable to centimetres. Active system uses active device on person, or objects to be protected (closed loop) No false alarms/ nuisance alarms. Sufficiently reliable to be used for shutting down the machine. must fail to safety
Geosteering - Tramguard TM Geosteering subsequently developed a product incorporating the concepts along with a number of improvements The NIOSH LF/closed-loop concept was combined with modern electronics/software and packaging technology Tramguard: mainly protected the CM Operator side (Due to the CM fatality history) MHSA approved the system in 2005, it has been installed on 5 mines and has +2000 hours run time
TramGuardTM for CM s CM Stop Zone Warning Zone Monitor Zone ID Zone Out-of Zone
HOW DOES IT WORK? There are many types of systems that have been developed over time. Radio frequency has been the basis of most of the systems. These systems have not been widely accepted due to electrical interferences, instability, technological problems and architectural problems. HAZARDAVERT is a system that uses magnetic fields generated by electronics to detect persons and equipment and to audibly and visually warn operators of persons entering a defined warning zone and then to stop equipment if a danger zone is entered.
SASOL (RSA) Basic Requirements For Proximity Detection Work on all underground machines Warn miners and operators Slow machines down, and then stop Multiple machines multiple people Every machine must respond to every miner Every miner must be individually warned Every operator must be warned of highest priorities Be active with two-way verification Be inherently fail-safe Marked zones must be robust
Frederick Mining Controls Steps up to the SASOL Challenge with HazardAvertTM Met all SASOL system requirements Included numerous features to make it user friendly Demonstrated in a mine section in January 2009
http://www.sacollierymanagers.org.za/publications
Negative Trial Findings Data collection still manual process need to change to remote downloadable system SOLUTIONS Wireless downloads Via PDA Data collection Via MARSS SAFETY SOFTWARE
FMC-Sasol Present Activity it Contracted to outfit another 30 sections Systems to be installed on continuous mining i machines, shuttle cars, load-haul- l dumps, p, roof bolters, and rotary breakers Outfitting 3,500 miners with Tracking PAD Lamps (TPL)
http://www.coalzoom.com CM Proximity Systems Deployed Underground in South Africa Thousands of miners have been seriously injured or killed by mining equipment and vehicles during the last few years. In South Africa, the mining sector is a major contributor to the economy, employing large numbers of people. Much emphasis is being placed on the mining companies by the South African Department of Minerals and Energy to improve the safety of people working on or around mining machinery. A large underground coal mining company in the RSA has recently issued a contract to Frederick Mining Controls, LLC of Huntsville, AL to provide proximity it detection ti systems for essentially 31 complete underground d machine sections, including continuous miners, shuttle cars, Load-Haul-Dump vehicles, roof bolters, and rotary breakers. The HazardAvert proximity detection systems to be used produce a magnetic field around the machines which is then detected by a sensing device that is integrated into the miners cap lamp. The miner is personally warned, the operator of the machine is warned, and automatic steps are taken to slow or stop the machine. The contract provides for outfitting more than 3,500 miners with the sensing devices. Sasol s decision to rollout into their mines follows a successful demonstration in their Twistdraai mine that was completed in January 2009. Sasol reported that the systems were reliable and consistent it twith no fl false indications idi to date. dt The HazardAvert systems have continued dto be used since the demonstration with no problems reported yet.
Continuous Mining i Machines The Collision Avoidance Systems started with Continuous Miners and the danger zones around the equipment.
Shaped Field Concept for Use During CM Cutting Provides Silent Zone within Red Zone All i hil i f h i di f CM Allows miner to see cutter while staying out of the turning radius of CM Machine stops if miner steps out of Silent Zone
Shuttle Cars NOW: ALL MACHINES ARE COVERED!
TECHNICAL CHALLENGES Coal Penetration and Zone Stability
MULTIPLE MACHINES AND MULTIPLE WORKERS Machine 1: DZ Machine 2: None Machine 1: WZ Machine 2: WZ Machine 1: DZ Machine 2: WZ Machine 1: None Machine 2: WZ Machine 1 Person 2 Machine 1: DZ Machine 2: DZ Person 3 Danger Zone (DZ) Person 1 Person 5 Warning Zone (WZ) Person 4 Machine 2 Machine 1: WZ Machine 2: DZ Machine 1: DZ: Person 1 / 2 / 5 WZ:Person3/4 Danger Zone (DZ) Warning Zone (WZ) Person 6 Machine 2: DZ: Person 4 / 5 WZ: Person 1 / 3 / 6
SYSTEM MANAGEMENT REPORT
Shuttle Car Danger Zone Violations For a period of 6 weeks 1200 1072 10 994 1000 9 8 800 7 651 677 6 600 5 Occurences400 4 224 3 167 200 66 103 2 59 62 60 1 0 0 r r a lt raaror t tisan M in udy p letor OCM pe Foer re Tima lteera tleotor haopeor ndra m en St CMr/A l l blarrat 1s tr Roolte SheCper SheCper utarcacpe e Total 2noofb d 1sofrO tsbo 2nhuttrOto 3ruttarOato Occurences d d Average Duration per Occurence
Continuous Miner Danger Zone Violations For a period of 6 weeks 120 100 80 60 Occurences40 20 0 4 93 97 13 5 9 57 42 16 15 0 0 10 9 8 7 6 5 4 3 2 1 0 ra t. t C r/aorom pe rato Arr tisan M in Foer re man e Study r r ttlerotor tleopor Caera tlerotor Cp ndra le CMlt Ti me haope oofb Roolteo tsfboope hulteshcapera blearer.. ut Total Average Sh ut Occurences Duration tr 1s d d 2n 1s 2n 3r d Ca per Occurence
SYSTEM SAFETY FEATURES Automatically slows and/or stops machine Stops machine if power is lost Stops machine if size of field reduces on any generator Stops machine if cable is cut or disconnected Stops machine if communication degrades Redundant d receivers (four for a CM or SC) Warns each machine operator Remote stop capability bl for miners and operators Stops machine if miner or operator TPL battery low
SYSTEM SAFETY FEATURES Multiple machines close together will not conflict Multiple miners, multiple machines no conflicts System housed in rugged X/P-F/P enclosures Armour added around X/P-F/P generators Designed for long life in vibration and shock Multiple signal handshaking to prevent errors High signal-to-noise ratio No exposed antennas System sees around corners
USER FRIENDLY SYSTEM Operator has display that reports status of field generators, communications, and warnings Miner is personally warned visually and audibly by TPL warning module Warnings regulated to not be a nuisance Silent Zone inhibits warnings Each generator has status indicators to support checking response Outputs provided to drive auxiliary warning devices TPL provides communications checks TPL has low battery warning to miner
SURFACE MINES AND PLANT Surface mines have the same exposure to TMM type accidents as the underground mines Machines are bigger, faster and suffer from blind spots Dusty conditions create visibility problems Man and Machine interaction areas are very aggressive e Plant areas are noisey and restrictive environments
SYSTEM FOR DRAGLINES Includes: Vehicle Alert Device (VAD) for detecting smaller vehicles Personal Alert Device (PAD) for detecting people
SYSTEM FOR HAUL TRUCKS
SYSTEM FOR FORKLIFTS YOU CANT FIX STUPIDITY!
MANAGEMENT CONSIDERATIONS Mature development, problems worked out Demonstrated on machines in 6 mines No impact to production Acceptance by miners Records all safety events, downloads wirelessly Provides for shaft clearance Automatically manage miner ID without any effort No calibration required for TPL s Machine IDs and Miner IDs are not used to accomplish control functions, thus eliminating a management task TPL Checkout Station and memory POD on system provide safety data for use by management to evaluate safety operation
CONCLUSIONS At last: A stable, fail to safe system is available The system can be altered to your specific requirements The system works for surface and underground The system integrates with your reporting / communication i systems The system can include tagging and tracking The system records events and chance takers are easily identified Shaft clearance is automated Lamp room control can be automated Access control can be integrated t Licensing can be integrated Key control is automated Medicals can be automated
QUESTIONS PLEASE? THANK YOU FOR YOUR KIND ATTENTION Acknowledgements: SASOL, FMC, ILIPS