BECSA Potential Energy Guide Hans Suurd Mechanical Superintendant , Wolvekrans Engineering 18 April 2013

Contents

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 2

Setting the scene Background Requirements Strategy Potential energy language Big six basics Booklet End result Going forward

Setting the scene

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 3

The inconvenient truth

The Mine Health and Safety Act No 29 of 1996 states:

Section 11. Employer to asses and respond to risk. (1) Every employer must -

(a) Identify the hazards to health or safety to which employees may be exposed while they are at work;

(b)Asses the risks to health or safety to which employees may be exposed while they are at work;

(c) Record the significant hazards identified and risks assessed; and

(d)Make those records available for inspection by employees

Potential energy fits this bill!

Background

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 4

The birth of the Potential Energy Guide was due to an action from the ICAM investigation for a permanent disability injury which occurred at Wolvekrans Colliery.

It was clear from the investigation that the artisans involved did not identify the potential energy hazard. The result was that no precautionary steps were taken to remove this hazard.

Where does potential energy feature in our safety systems?

Requirements

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 5

The guide must:

• Be a tool not a rule

• Encourage thinking not spoon feeding

• Ask questions, not give generic answers

• Be blue, not white collared, to create potential energy know how on shop floor level (what does this mean?)

• Not just another campaign, but embedded as second nature

• Be an effective communication tool to all artisans

Strategy

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 6

“The single biggest problem in communication is the illusion that it has taken place”

- George Bernard Shaw –

The Potential Energy communication strategy:

• Develop a Potential Energy language •The way we talk Potential Energy

• Communicate with pictures and examples •A picture paints a thousand words •What are the known low hanging “fruit”

Potential energy language

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 7

The theoretical explanation:

• Power or energy that has not been used or dissipated

• Energy possessed by a body as a result of its position or condition rather than its motion

• The ability of a system to do work due to its position or internal structure

• Energy difference between the energy of an object in a given position and its energy at a reference position

How do we translate this into the everyday work of an artisan?

Potential energy language

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 8

The practical answer

• Potential energy is like a lion in a cage

• The animal is majestic and people pay to see it

• In the cage it cannot harm us

• We can view the animal from close range

• Potential energy in our equipment is the same.

• In normal operations, energy is controlled and perform work.

• We require to harness it to power our mine!

Lions safely behind a fence

Potential energy language

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 9

What is the big deal?

• What happens if: – the lion escapes from the cage? – we need to enter its cage?

• A lion is a wild animal and remains unpredictable

• But it can be done safely, with the correct preventative actions in place

• If a machine brakes down

– potential energy can escape! – we have to “enter” the potential

energy line of fire!

Do you want to enter this cage?

Big six basics

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 10

Unfortunately like in a zoo, we do not have only one dangerous animal but the big six

•Gravitational Potential Energy (The Elephant)

•Elastic Potential Energy (The Buffalo)

•Electric Potential Energy (The Leopard)

•Chemical Potential Energy (The Rhino)

•Thermal Potential Energy (The Lion)

•Nuclear Potential Energy (The Hippo)

When dealing with each potential energy source you need to know how they react and how to protect yourself against it!

Big six basics

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 11

Gravitational Potential Energy

The elephant

• An elephant will trample you and crush your bones

• Look out for heavy objects on elevated levels

– Can they fall? – Can they collapse? – Can you get caught?

• Do not get your body parts or body caught below or between heavy objects

• You will be crushed!

Big six basics

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 12

Elastic potential energy

The buffalo

• Buffalos are known for their short tempers

– A buffalo can charge and destroy anything in its path

• Elastic potential energy – Is stored in springs / cylinders

and ropes – It can release without warning.

• Parts and components will shoot in random directions

• If you are in the way they will go straight through you!

Big six basics

Name, Position, Department, Day Month Year Slide 13

Electric Potential energy

The leopard

• Leopards are one of the best hunters in the wild.

• It is renowned for stalking its prey – They are camouflaged to

perfection. – They catch their prey unaware

• Electrical Potential energy is exactly the same

– you cannot see it, – you cannot hear it,

• You will only feel it and then it is too late!

Big six basics

Name, Position, Department, Day Month Year Slide 14

Chemical Potential energy The rhino • Rhinos are calm animals which

scare of predators with their horns – It will however not think twice if

it is threatened – It will destroy anything in its

path.

• On its own, chemicals are safe until:

– Different chemicals are mixed – Pressurized – Heated and ignited

• It will explode / burn and destroy everything in its path

Big six basics

Name, Position, Department, Day Month Year Slide 15

Thermal Potential energy

The lion

• Lions are the killing machines of Africa

• Constantly hunting for weak prey to pounce on

• Thermal Potential energy is also constantly looking for the weakest spot in the system.

• When they eventually escape they release with fury

Big six basics

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 16

Nuclear Potential Energy

The Hippo

• Hippo is the animal that kills the most people in Africa

• It is renowned to be extremely dangerous

• It kills without blinking

• Nuclear potential energy is also dangerous and deadly.

• There are no second chances when dealing with radioactive sources

Booklet

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 17

Potential Energy guide characteristics

• A5 ring bind file

• Quality color printed for clarity

• Pictures to communicate risk

• Blank pages for notes

• Actual incidents noted

• Color coded energy types

Booklet

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 18

Identify as much as possible known potential Energy risks in each work area

• Communicate risk with actual photos and short description

Booklet

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 19

Big six identified, colour coded and exposed

Booklet

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 20

Booklet pages printed on practical A5 pages

Booklet

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 21

6 Different booklets identified with specific risks for each area

• Opencast operations – BCM equipment • Opencast operations – EME equipment • Opencast operations – Track machines • Opencast operations – Services • Plant operations • Underground operations

End result

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 22

The reasonable man’s test

• 80% of our hazards covered with one tool

The potential energy guide delivers:

• Potential Energy identification training tool, useable by everybody in the organisation.

• Quick reaction and easy communication of potential energy incidents or injuries.

• Organizational learning and memory of all potential energy incidents / injuries and identified hazards.

• A comprehensive visible list of potential energy situations.

Going forward

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 23

The next step for potential energy:

• Proactively develop links to safety procedures for the elimination and control of potential energy hazards

• Posters can be developed and displayed in workshop areas for increased awareness

• Equipment can be marked with big six logos

• Monthly themes on one of the big six basics

Questions and comments

Hans Suurd, Mechanical Superintendant, Wolvekrans Engineering, 18 April 2013 Slide 24