Electrical Ex Regulation in NSW Mines

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Electrical Ex Regulation in NSW Mines
UN ECE Geneva, November 2007

• John Francis Waudby
• Senior Inspector of Electrical Engineering
• Mine Safety Operations

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Overview

• Introduction NSW Mines
• Electrical equipment in mines
• Regulation and the use of IEC Standards and
  Schemes

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Mining in NSW

• Coal
• Metalliferous
• Quarrying
• Sand Dredging
• Opals
• Fatality rate 1/year
• LTIFR 16 per million hours
• Last fatality 09/01/2007

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Mining in NSW

• Total (continuous intermittent) 1700
• O/C Coal mines 37
• U/G Coal mines 34
• Coal production 150,000,000 tonnes / annum
• Coal U/G production 50,000,000 tonnes / annum
• Coal employment 13,000

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Role of the NSW Mining Regulator

• Mine site assessments
• Investigations
• Standards legislation development
• Communication to all stakeholders
• Industry support infrastructure

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Role of the NSW Mining Regulator

• Strategic Plan
• Standards Legislation Program
• Communication Program
• Industry Infrastructure Support Program
• Special Projects
• Mine Safety Technology Centre

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Electrical Engineering Safety

• Prevention of gas and/or dust explosions
• Prevention of electric shock and burns
• Prevention of fires
• Prevention of unintended operation of equipment
• Provision of electrical safeguards

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Coal Mining Electrical Engineering Safety
Performance

• Last fatal accident 23 years ago
• Last electrocution 24 years ago
• Last fatal explosion 28 years ago

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Coal Mining Electrical Engineering Safety
Performance

• Explosions / major gas ignitions
• 8/1/1979 - West Wallsend
• 24/7/1979 Appin
• 28/6/1995 - Endeavour
• 12/12/1997 - Munmorah

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NSW Mining Regulator - Experience with Electrical
Equipment
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Approval of Electrical Equipment

• Explosion protected equipment
• Electrically powered mobile machines for use U/G
• Electrically powered mobile machines for use in
  O/Cs
• Portable apparatus for use underground
• Electrical protection relays for use underground

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Approval of Electrical Equipment

• Electrical protection relays for use in open cuts
• Electric cables used in hazardous zones
• Caplamps
• Gas detectors
• Electric shotfiring equipment (U/G O/C)

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Approval of Electrical Equipment

• Based on a test report from a recognised test lab
• Reviewed by a competent engineer
• Signed by the Chief Inspector of Coal Mines
• Approval documents and number issued (no time
  limit)
• Database kept

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Approval of Electrical Equipment

• Some approvals were issued with non - compliance
  to standards
• Approval was initially free
• Conditions of manufacture / use were specified
• Approval related to use pit worthiness

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Approval of Electrical Equipment

• It was as a result of serious accidents
• One element in prescriptive technical regulation
• It was based on published standards
• Supported by competent mine electrical engineers
• Supported by an approved workshops scheme

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Approval of Electrical Equipment

• Approval / competency schemes were credible
• 1988 Risk assessment introduced to the coal
  industry

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Evolution of approvals

• 1991 ALL approvals were subject to review
• Hazardous zone cables were deemed to be approved
• Approval scheme became stressed.
• Other organisations appointed as approvers

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Evolution of approvals

• Role of the regulator
• quality auditor
• database manager
• ad-hoc technical review
• By 1998 the approval scheme had deteriorated

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Evolution of approvals

• Equipment approved that was not Ex
• Approval processes were not good enough
• A new strategic direction was required

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From Approval to Certification

• Queensland had accepted CoCs as early as 1994
• NSW looked to follow Qld
• Active participation in Ex management schemes
• By 1998 risk assessment was well established
• In 1999 regulations changed along with approval

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From Approval to Certification

• Other equipment was required to comply with
  specified standards
• Portable apparatus had to be used within a
  management scheme

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From Approval to Certification

• 2002 - confident in the ANZ Ex scheme and the ANZ
  Ex CBs
• AUS Ex and ANZ Ex CoCs deemed suitable (with
  conditions)
• The IEC Ex scheme commenced acceptance extended
  to Australian issued IEC Ex CoCs

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From Approval to Certification

• Extensive review of the IEC Ex scheme conducted
• Canvassed industry via a discussion paper for
  full IEC Ex acceptance
• Legislation changed in December 2006
• approval became registration
• Ex equipment was not included
• Ex equipment had to meet specified criteria

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From Approval to Certification

• Continuing to participate in Ex scheme MCs
• Continuing to review IEC Ex CoCs and ATRs
• Planned random audits of IEC Ex ATRs and CoC s
  from ALL types of IEC bodies
• Supported by a specific minesite program.

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Overview Approval to Certification

• Approval and competency schemes evolved
• Legislation embraced contemporary OHS Mngt
• National International certification schemes
  matured
• Industry culture evolved
• All of this allowed the DPI to embrace
  certification
• Redirect resources to mine site activities.

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Summary Regulation Ex equipment

• Coal mine explosions are high risk events.
• Ex is a critical risk control
• Additional scrutiny is needed.
• The scrutiny must be credible
• Ex equipment must be Ex throughout its life.
• When new, it is as good as it gets
• Ex supported by the correct regulatory
  requirements

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Ex equipment - Additional scrutiny

• Be applied at the proper points of the equipment
  life cycle.
• Support all activities throughout the life cycle.
• Support the hierarchy of risk controls
• Provide for a level of risk less than or equal to
  what we do now
• Recognise the harsh mining environment
• Be competent
• Be credible

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Ex equipment - Credible scrutiny

• Set standard
• Consistent and repeatable
• Competent people
• Proper procedures
• Fit for purpose equipment facilities
• Managed work environment
• Ethical work environment

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Principles for managing Ex equipment

• Ex equipment to be certified
• Suppliers of equipment to provide sufficient
  life-cycle information
• Requires mines to have Ex repairs done at
  licensed facilities
• Requires a competent mine electrical engineer
• Requires an Electrical Engineering Management
  Plan
• Requires mines to establish electrical competency
  requirements

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IEC Ex Support for the regulator

• IEC Standards and Ex Schemes provide
• Standards of design
• Competent designers
• Third party design verification
• Confidence in the manufacture
• Ex equipment arrives at the mine in an Ex
  condition.

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IEC Ex Support for the regulator

• Equipment is installed, commissioned, maintained
  used properly
• Provision of information
• Selection, installation, commission, inspect and
  maintenance standards
• Competency for life-cycle management (proposed)

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IEC Ex Support for the regulator

• Ex management dictates overhaul and repair
• Equipment overhauled and repaired back to its
  certified state
• Provision of information
• Repair and overhaul standards
• Independent assessment of competencies
• Independent assessment of workshops
• Facilities, tools, equipment and measurement
• Work processes, competencies and management
  systems

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Summary - IEC Ex supporting the regulator

• The IEC Ex standards and IEC Ex schemes provide
  for
• provision of information
• life cycle management
• appropriate independent assessment at
  appropriate points
• All of the above is required by contemporary OHS
  legislation

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A regulator using IEC Ex

• Currently the DPI
• has accepted equipment certified under the IEC Ex
  scheme.
• is monitoring the implementation of the IEC Ex
  services scheme
• IEC Ex CoCs have been accepted via a gazette
  notice
• The regulator still retains prohibition powers

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OBSERVATIONS

• IEC Ex certification of equipment - Very
  confident that it is Ex
• Regulators can use this as a minimum expectation
• The extent of national regulation is dependent on
  safety culture
• Countries with no Ex certification can use the
  IEC Ex scheme with confidence
• Countries with developed national schemes can
  easily transition to IEC Ex
• Countries who rely on IEC Ex must participate

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CONCLUSIONS

• The IEC Ex standards and schemes can aid
• Life cycle management of Ex equipment
• The regulators aims for electrical engineering
  safety
• A mine operators fulfilment of OHS obligations
• An equipment suppliers fulfilment of OHS
  obligations
• Credibility of the schemes is a critical
  component
• We are committed to a highly credible IEC Ex
  scheme

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Other information Contact details

• Other Information
• Technical and Safety Regulation of the Energy
  Sector
• Discussion paper at www.ena.asn.au
• Contact details
• Website www.minerals.nsw.gov.au/safety
• Email john.waudby_at_dpi.nsw.gov.au