Eric Tomicek Global Sales Manager, Australian Diversified Engineering
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Ramsay – Diamond Wire Saw Mobile Unit
Matt Ramsay
Drilling Superintendent – Gas, Anglo American – Moranbah North Mine
The Problem
The rehabilitation of redundant Mine Service boreholes requires the shearing and removal of cemented 20” Steel casing at 1.5m below the ground surface.
This process previously required the entry into the excavation and the risk associated with the manual handling of a hydraulic saw device to cut the casing at required position.
During this cutting process the operators experienced several rotating blade failures that resulted in small shard of steel ejected from the saw blade and contacted the operator’s glove.
The Solution
The strategy to eliminate the hazards identified from investigation of the event; it was actioned to source an alternative device with the capacity to efficiently shear 20” cement encased steel casing, eliminating manual handling, exposure to excavation; via the functionality of remote operation.
The Diamond Wire Saw (DWS) device was identified, assessed and then progressed to primary design functional testing phase in December 2018. With positive observations of improved safety, efficiency and operational performance parameters.
During the trial and testing period, this involved collaboration and engagement of DWS OEM and test operators. The collaboration of stakeholders delivered engineering inputs combined with the collation of test operator feedback facilitated continuous improvement of the DWS device’s re-purposed application into an integrated mobile unit.
The Benefits
The field functional testing and operation of the DWS mobile unit demonstrated:
- Elimination – of traditional rotating blade failure hazard – Guarded Diamond impregnated cable
- Elimination – of manual handling – proximity protected – remotely controlled loader positions and retrieves DWS
- Elimination – CMW entry into excavation – DWS utilizes self-attachment / release function
- Elimination – of manual handling – proximity protected – remotely controlled loader secures the casing during cutting process and relocates to waste transport
- Separation – remote operator console – remove CMW exposure to line of fire
- Separation – remote operator console – remove CMW exposure to excavation
- Operational effectiveness performance realized an increase of 60% on previous methodology
David Roberts – Maintenance Fitter
Dave Champion – HSET Manager, Peabody-Millennium Mine
Stuart Sephton
National Plastics & Rubber Pty Ltd
Blair Whitney & Ben Murphy
Coronado Global Resources Inc
Wilkie – Workshop Wheel Chock
Luke Wilkie, Maintenance Manager, Anglo American Dawson Mine
Dave Zanette
Project Supervisor, BMA
Andrew Batterson
BMA Engineering
The Broadmeadow Battery Electric Vehicle project was initiated to address the residual Similar Exposure Groups (SEG) exposure to Diesel Particulate Matter (DPM).
Over the last 3 years, Broadmeadow (BRM) has successfully completed a number of projects to reduce occupational exposures to DPM for the underground SEGs. These initiatives have resulted in ongoing improvement to the mine’s total exposure profile, which we understand is now approximately one third of most other underground coal mines in Queensland.
After exhausting all options for a suitable lower emissions diesel engine package options for underground personnel transporters BMA initiated an aggressive schedule for implementation of an underground battery electric personnel transporter.
With the local market opportunities exhausted, the BRM team sourced international suppliers with previous experience in manufacturing electric personnel transporters. A supplier was selected and a commitment to implement a surface trial was to commence in FY19.
Broadmeadow set up and implement a team to carry out the FAT testing and trial of the vehicle, the trial included but not limited to determining all required safety, legislative, performance and failure modes required by stakeholders for the trial to be successful. In the back ground the engineering team and supplier conducted the necessary detailed assessments and engineering modifications against current Australian Standards and legislation for the suitability of implementing an underground trial.
BRM has successfully completed surface and underground trials proving the safety, reliability and performance of a battery electric vehicle whilst also validating the extremely low operating cost.
The next phase of the project is to implement full production trials by removing all diesel powered personnel transporters from a development section of the mine to validate the DPM exposure reductions.
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