blast management plan 2012 2015 -...

Environmental Blast Management Plan

Document Owner Issue Number

Date Next Review Date Page

Environmental Advisor 00 16/10/2012 16/10/2015 1 of 61

Environmental Management System

Integra Coal Operations Pty Ltd

BLAST MANAGEMENT PLAN

2012 – 2015

Doc No: EMP_2005 –Blast Management Plan

Doc Owner: Environmental Advisor – Integra Coal Operations

Approval: Group Environment Manager

Vale Australia Operations

Signed:

21/08/2013

Date:

Revision Issue Date Originator Reviewed Approved

00 16/10/2012 Terrock Integra





Table of Contents

Page 1. INTRODUCTION ..............................................................................................................................4

1.1 BACKGROUND .................................................................................................................4

1.2 STATUTORY REQUIREMENTS .......................................................................................4

1.3 RELATIONSHIP WITH OTHER ENVIRONMENTAL DOCUMENTATION .......................5

1.4 PLAN OBJECTIVES AND PERFORMANCE INDICATORS ............................................6

2. EXISTING AND PLANNED OPERATION ..................................................................................... 10 3. ROLES AND RESPONSIBILITIES ................................................................................................ 12 4. MONITORING ................................................................................................................................ 15 5. MANAGEMENT MEASURES ........................................................................................................ 16

5.1 PREVENTATIVE MEASURES ....................................................................................... 16

5.1.1 ENVIRONMENTAL BLAST DESIGN ............................................................................. 16

5.1.1.2 GROUND VIBRATION ................................................................................................... 19

5.1.1.3 AIRBLAST OVERPRESSURE ....................................................................................... 21

5.1.1.4 FLYROCK ....................................................................................................................... 22

5.1.1.5 DUST AND FUMES........................................................................................................ 27

5.1.1.6 ARTC RAIL LINES AND INFRASTRUCTURE .............................................................. 27

5.1.1.7 ROAD CLOSURE PROCEDURES ................................................................................ 28

5.1.1.8 REFIRES OR MISFIRES ............................................................................................... 28

5.1.2 DESIGN IMPLEMENTATION ......................................................................................... 29

5.2 POSTPONING A BLAST ................................................................................................ 30

5.3 CORRECTIVE MEASURES ........................................................................................... 30

6. COMPLAINTS HANDLING ............................................................................................................ 32 7. REPORTING AND REVIEW .......................................................................................................... 34

7.1 REPORTING .................................................................................................................. 34

7.2 PLAN REVIEWS ............................................................................................................. 34

8. REFERENCES .............................................................................................................................. 35 9. GLOSSARY ................................................................................................................................... 36 FIGURES

Figure 1-1 BMP Connections to other environmental documents ............................................................. 5 Figure 2-1 Integra Coal Blast Monitoring Locations ................................................................................ 11 Figure 5-1 Blast Design Flowchart ........................................................................................................... 18 Figure 5-2 The sensitivity of airblast to stemming height ........................................................................ 22 Figure 5-3 Minimum recommended Blast Exclusion Zones .................................................................... 24 Figure 5-4 The sensitivity of the maximum throw to stemming height..................................................... 25 Figure 5-5 Stemming ejection/Stemming height relationship .................................................................. 26 Figure 5-6 Open Cut Blasting Flowchart .................................................................................................. 28 Figure 6-1 Complaint management process flow chart ........................................................................... 33





TABLES

Table 1-1 Plan Objectives and Performance Indicators ........................................................................... 6 Table 1-2 Integra Coal Blasting Criteria (Project Approval Table 9) ........................................................ 7 Table 3-1 Roles and Responsibilities ..................................................................................................... 12 Table 5-1 Open Cut nominal blasting specifications .............................................................................. 16 Table 5-2 Recommended Peak Ground Vibration Levels ...................................................................... 20

APPENDICES

APPENDIX A - APPROVAL CONDITIONS AND EA COMMITMENTS .......................................................... 38 APPENDIX B - UNDERGROUND TARP ......................................................................................................... 42 APPENDIX C – INTEGRA COAL OPEN CUT: BLAST FUME MANAGEMENT STRATEGY ........................ 43





1. I n t r o d uc t i o n

1.1 Background

This Blast Management Plan (BMP) forms part of a series of Environmental Management Plans for

the Vale Integra Mine. It encompasses blast management across both the Integra Coal Open Cut

and Integra Coal Underground Sites, collectively known as the Integra Complex.

Current and approved operations within the Integra Complex include the North Open Cut, the

Underground Mine, South Pit and the Extended South Pit (Western Extension). Relevant

infrastructure associated with the Complex includes the Coal Handling and Preparation Plant (CHPP),

underground ventilation fan site, tailings dams and associated clean and dirty water storage facilities.

Whilst this BMP is dynamic and changes will be made as warranted over time, the formal life of this

Plan is three years, beginning on the date of formal acceptance of the plan by the Department of

Planning and Infrastructure (DP&I).The document will be reviewed and amended as outlined in

Section 7.2.

1.2 Statutory Requirements

Surface Blasting operations at the Complex must be conducted in accordance with the provisions of:

- NSW Department of Planning & Infrastructure - Project Approval, Integra Mining Complex

- Coal Mine Health and Safety Act 2002 – (CMHSA 2002)

- Coal Mine Health and Safety Regulation 2006 – (CMHSR 2006)

- Work Health and Safety Act 2011

- Work Health and Safety Regulations 2011

- Explosives Act 2003

- Explosives Regulations 2005

- MDG 1012 Use of explosives in underground coal mines

- AS 2187.1 - 1998: Explosives – Storage, Transport and Use, Part 1 - Storage

- AS 2187.2 – 2006: Explosives – Storage, Transport and Use, Part 2 – Use of Explosives

- AS 2187.0 –1983: Storage transport and use – Terminology

- Australian Explosives Code – Third Edition – April, 2009

- Integra Explosives Hazard Management Plan (HMP_2001)

- Integra Road Closure Management Plan

- Australian Explosives Industry and Safety Group Inc (AEISG) Code of Practice

The Integra Mine Complex Project Approval (08_0101 and 08_0102), dated 26 November 2010,

Condition No. 19 of Schedule 3 requires preparation of a Blast Management Plan. All of the

requirements for the Plan are addressed in this document, as detailed in Appendix A. Project

approval was based, amongst other things, on the Government‟s consideration of the two

Environmental Assessments (EAs) that accompanied the application for the projects, namely

Proposed Integra Underground Coal Project, July 2009, and Integra Open Cut Project, June 2009.

The Statement of Commitments in the Open Cut Project EA assessments makes certain

commitments in respect of blast management at the Complex. Such commitments have been





addressed in this BMP. Appendix A sets out the relevant commitments and where they are addressed

in the BMP.

1.3 Relationship with Other Environmental Documentation

The relationships between this BMP and other environmental documentation held by Integra are

shown conceptually in Figure 1-1.

Figure 1-1 BMP Connections to other environmental documents

Note: Blast Fume Management Strategy is appended to this Blast Management Plan as approved by

Department of Planning and Infrastructure.

The Underground TARP referred to in the above diagram can be found in Appendix B.





1.4 Plan Objectives and Performance Indicators

The objectives of the Blast MP and the associated performance indicators are set out in Table 1-1.

Table 1-1 Plan Objectives and Performance Indicators

Objectives Performance Indicators

Compliance with legislative requirements. Airblast or ground vibration not to

exceed criteria nominated in Project

Approval, namely Table 9 – Blasting

Criteria (condition 11 reiterated below

this table):

Blasting to be conducted in accordance

with Project Approval Blasting Criteria

(conditions 11, 12, 13) and Operating

Conditions (16 - 18) (outlined below);

No flyrock beyond mine boundary, or

unplanned flyrock events;

Minimisation of off-site odour, dust and

fume emissions.

Control the blast process from design to

implementation, initiation and evaluation.

Comply with Project Approval requirements.

Identify the risks and hazard associated with

blasting, including control and/or mitigation.

Safely blast and comply with Project

Approval requirements.

Implement best practice measures for the

management and minimisation of dust and

noxious fumes from surface blasting.

Mitigation of dust and fumes.

Assure the safety of the public, site

personnel and surrounding properties from

flyrock.

No flyrock incidents resulting in personal

injury or property damage.

Establish effective communications and

active links between the Open Cut and

Underground Operations.

Effective communication.

Ensure the safe operation of the Integra

Underground Operations (IUO) under Open

Cut blasting activities

Effective communication.

No blast related incidents involving IUO.

Comply with relevant coal industry

legislation

Compliance with legislation.

Limit the risk of damage to surface No blast vibration exceedences or flyrock





Objectives Performance Indicators

infrastructure by controlling blast vibration

and flyrock at:

Possum Skin Dam;

Tailings Dams;

Envirogen Power Generation Site;

Overland Conveyor Belts;

Underground portal and surrounding

highwall;

ARTC Main Northern Rail Line

cuttings, embankments and

infrastructure; and

New England Highway and Local

Public Roads.

incidents.

Table 1-2 Integra Coal Blasting Criteria (Project Approval Table 9)

Receiver

Airblast Overpressure (db(Lin Peak))

Ground Vibration (ppv(mm/s)

Allowable Exceedance

Residence on privately-owned land

115

5

5% of the total number of blasts over a period of 12 months

120

10

0%

Main Northern Railway culverts and bridges

-

25

0%

All public infrastructure

-

50

0%

Table 1-2 outlines blasting criteria as per Integra Coal Project Approval 08_0101 and 08_0102,

however, these criteria do not apply if the Proponent has a written agreement with the relevant

landowner or infrastructure owner to exceed the criteria, and the Proponent has advised the

Department in writing of the terms of this agreement.





Project Approval - Conditions:

12. The Proponent shall only carry out blasting on site between 9am and 5pm Monday to Saturday inclusive. No blasting is allowed on Sundays, public holidays, or at any other time without the written approval of the Director-General.

13. The Proponent shall not carry out more than:

(a) 1 blast a day in the northern mining area unless an additional blast is required following a blast misfire;

(b) 2 blasts a day in the existing Camberwell south pit, and then 1 blast a day when the mining moves from this pit into the western mining area unless an additional blast is required following a blast misfire; and

(c) 10 blasts a week on site, averaged over any 12 month period.

14. If the Proponent receives a written request from the owner of any privately-owned land within 2

kilometers of the approval open cut mining pits on site for a property inspection to establish the

baseline condition of any buildings and/or structures on his/her land, or to have a previous

property inspection report updated, then within 2 months of receiving this request the

Proponent shall:

(a) commission a suitably qualified, experienced and independent person, whose appointment

has been approved by the Director-General to:

establish the baseline condition of the buildings and/or structures on the land or update the previous property inspection report; and

identify any measures that should be implemented to minimise the potential blasting impacts of the projects on these buildings and/or structures; and

(b) give the landowner a copy of the new or updated property inspection report.

15. If any landowner of privately-owned land within 2 kilometres of any approved open cut mining

pit on site claims that the buildings and/or structures on his/her land have been damaged as a

result of blasting on site, then within 2 months of receiving this request the Proponent shall:

(a) commission a suitably qualified, experienced and independent person, whose appointment

has been approved by the Director-General to investigate the claim; and

(b) Give the landowner a copy of the property investigation report.

If this independent property investigation confirms the landowner‟s claim, and both parties

agree with these findings, then the Proponent shall repair the damages to the satisfaction of the

Director-General.

If the Proponent or landowner disagrees with the findings of the independent property

investigation, then either party may refer the matter to the Director-General for resolution.

16. The Proponent shall:

(a) implement best blasting management practice on site to:

Protect the safety of people and livestock in the surrounding area;

Protect private or public property in the surrounding area;

Minimise the dust and fume emissions of the blasting; and





(b) co-ordinate the blasting on site with the blasting at nearby mines (including Ashton, Rix‟s Creek and Mt Owen mines) to minimise the cumulative blasting impacts of the mines;

(c) operate a suitable system to enable the public to get up-to-date information on the proposed blasting schedule on site; to the satisfaction of the Director-General.

17. The Proponent shall not undertake blasting within 500 metres of:

(a) Middle Falbrook Road or Stony Creek Road without the approval of Council;

(b) the New England Highway without the approval of the RMS; and

(c) the Main Northern Railway without the approval of the ARTC.

18. The Proponent shall not carry out blasting in the northern or western mining areas that is within 500 metres of any privately-owned land or land not owned by the Proponent unless:

a) the Proponent has a written agreement with the relevant landowner to allow blasting to be carried out closer to the land, and the Proponent has advised the Department in writing of the terms of this agreement; or

b) the Proponent has:

Demonstrated to the satisfaction of the Director-General that the blasting can be carried out without compromising the safety of the people or livestock on the land, or damaging the buildings and/or structure on the land; and

Updated the Blast Management Plan to include the specific measures that would be implemented while blasting is being carried out within 500 metres of the land.





2. E x i s t i n g a n d P l a n n e d O p er a t i o n

The Complex comprises the following major areas and infrastructure:

• North Open Cut (NOC), which is the most northern open cut mining area, located between the site tailings dams and a major mine water storage dam known as Possum Skin Dam;

• South Pit, which forms a significant part of the overburden emplacement area for the Extended South Pit (Western Extension);

• Extended South Pit (Western Extension) will be the primary area of open cut mining activities and will operate 24 hours a day;

• Underground workings, currently longwall mining in the Middle Liddell seam with development works occurring to access the coal resource in the Hebden Seam and approval to mine in the Barrett seam;

• Underground related surface infrastructure, which includes administration facilities, gas drainage infrastructure and ventilation shaft site along with water management structures;

• The Coal Handling & Processing Plant (CHPP) that receives, stockpiles and washes coal from both the underground and open cut operations and loads product coal via the rail load out facility into trains for transport to the port of Newcastle;

• Tailings dams; and

• Underground/open cut related facilities, which includes administration areas, workshop and hydrocarbon storage areas.

The state of operations at the Integra Open Cut is shown in Figure 2-1. Blasting operations planned

under this BMP will occur in the NOC and Western Extension of the South Pit.





Figure 2-1 Integra Coal Blast Monitoring Locations





3. R o l es a n d Re sp o n s i b i l i t i es

The roles and responsibilities of Integra staff at the Complex in respect of this BMP are presented in

Table 3-1.

Table 3-1 Roles and Responsibilities

Role Responsibilities

Operations Managers (Open Cut and Underground)

• Ensure adequate resources are available to enable effective implementation of this BMP; and

• Ensure implementation of the BMP.

Sustainability Manager

• Authorise the BMP and future amendments.

Environmental Superintendent

• Review the BMP as required;

Act as the interface for environmental matters between government authorities, private industry, contractors, community groups and the wider community;

• Inform the relevant Operations Manager, Manager of Mining Engineering and Sustainability Manager of unexpected or serious environmental impact issues pertaining to blasting; and

• Promptly notify the relevant regulatory agencies of any incidents or non-compliances.

Open Cut Operations Manager

• Ensure that all individuals from the open cut workforce with responsibilities under this Plan are competent to carry out those responsibilities;

• Ensure that all relevant open cut personnel are aware of, and understand, their responsibilities as stated in the BMP;

• Ensure that training material is developed and provided, commensurate with target group, (e.g. workforce, supervisors, persons delegated specific duties under the plan); and

• Ensure any systems and procedures are developed and implemented in accordance with the requirements of the BMP.

Underground Operations Manager

• Review the Blasting Management Plan, its updates and associated standards and procedures;

• Ensure that all individuals from the underground workforce with responsibilities under this BMP are competent to carry out those responsibilities;

• Ensure that all relevant underground personnel are aware of, and understand, their responsibilities as stated in the BMP;

• Ensure that training material is developed and provided, commensurate with the target group, (e.g. workforce, supervisors, persons delegated specific duties under the plan);

• Ensure any systems and procedures that are developed and implemented in accordance with the requirements of the Plan are






communicated to relevant personnel; and

• Ensure that all risk assessment processes are formally documented.

Drill and Blast Engineer

• Co-ordinate blasting on site (email notification) with the blasting at nearby mines (including Ashton, Rix‟s Creek, Glendell and Mt Owen Mines) to minimise the cumulative blasting impacts of the mines. A minimum 5 minute delay between Integra and surrounding mine blasting is adopted;

• Ensure correct notification is provided to potentially affected persons as nominated on the list of neighbours to be contacted prior to blasting, including information relating to blast location and safe area for blast evacuation; and

• Ensure blast design is carried out to minimise risks to underground and infrastructure and surface personnel.

Drill and blast coordinator

• Ensure pre blast notifications have been conducted;

• Ensure that the traffic control protocol is in place;

• Review weather conditions and blast in accordance with relevant Trigger Action Response Plans(TARPS); and

• Ensure all blast notification signs are updated prior to each blast.

Shot firer • Receive notification from all sentries that they are in place and the blast site is evacuated and secure;

• Postpone the blast or give authorization (to be in the blast zone if shot is already fired but not cleared) if contacted by the underground sentry for an emergency evacuation;

• Stand down all sentries after the “all clear”; and

• Where an underground sentry is required:

• Receive notification from the underground sentry that the underground mine is prepared for the shot

• Notify the underground sentry that the shot has been cleared.

• Give warning to the underground sentry to evacuate those personnel above ground if dust/fumes change direction and travel towards the underground portal

Undermanager • Receive information from the Drill & Blast Engineer pertaining to the blasting activities in the open cut;

• Ensure all personnel in his/her district with the potential to be impacted by the shot are aware of the time of a shot and are prepared to evacuate if necessary;

• Have a man stationed near the phone during a blast; and

• In the event of a planned evacuation, to account for all personnel in their section and organise the evacuation.

Underground Sentry • If workers are remaining underground during a shot, the Underground Sentry must 'no road' A and B Portals and position themselves at the Underground Sentry's station to stop any inadvertent access to the






restricted blast zone;

• Receive from all districts a phone call signalling they are prepared for the blast and to relay this information to the Shotfirer;

• Contact the Shotfirer in the event of an emergency to postpone the shot if anyone must be evacuated from the underground mine;

• Give the "All Clear" to each district after the Shotfirer has cleared the shot; and

• Relay an emergency evacuation order from the Shotfirer to all affected districts.

Mine Surveyor • Provide and maintain accurate mine plans; and

• Accurately mark out and record each blast pattern according to the blast design.

Surface Sentries/

Road Guards

• Contact the Shot firer to confirm he/she is in place and his/her section of the Pit or road is cleared for firing;

• Hold traffic until the „all clear‟ is given; and

• Stand down once given the „all clear‟ and permit normal traffic flow.

Employees and

Contractors

• Work in accordance with standards and requirements of the BMP and associated standards and procedures; and

• Remove their own personal tag from the tag boards in the event of an underground evacuation (planned or unplanned).





4. M o ni t or i n g

The airblast and ground vibration from all blasts are monitored with an automatic triggering system at

the following locations (as shown in Figure 2-1):

Bridge, Cheetham, Cherry, Dulwich, Craven, Lambkin, Langdon, McInerney, Moran, Possum Skin

Dam, Tailings Dam 2 and Watling.

The wave traces of the measurements recorded are inspected to ensure they reflect a blast event and

are not due to a false (non-blast) trigger such as a wind or person/animal induced event. The peak

values measured of blast events are compared to compliance limits (refer Table 1-2).





5. M an a ge me n t M eas ur e s

5.1 Preventative Measures

Blasting operations are managed by deployment of an engineered blast design. Quality control

activities are conducted during the deployment to ensure the accuracy of explosive loading.

The „startling‟ effect of blasts on neighbours is mitigated by:

Prior to blasts, notifying neighbours on a contact list. In the event of a blast being changed (delayed or advanced) by 30 minutes or greater, SMS messages are to be sent to Steven and Carol Ernst on mobile numbers provided by them, as long as they reside at 5850 New England Highway Camberwell NSW 2330; and

For planned blasts between 9am and 12noon – notification is required the day before in the morning (not the afternoon before).

For planned blasts between 12noon and 5pm – notification is required the morning of the blast.

Liaising with Drill & Blast Engineers/Co-ordinators at adjacent mines to co-ordinate blast times as per FRM_2466.

When blasting within 500m of Stoney Creek Road (or within 500m of any other road impacted as mining progresses) road closures will be required to minimise risk associated with flyrock. Authority for road closures will be gained from Singleton Shire Council (SSC).

5.1.1 Environmental Blast Design

Each blast is designed according to the Blast Design Flowchart shown as Figure 5-1. The blast

specification for each blast is designed to ensure compliance with ground vibration and air blast limits

to ensure the safety of site personnel and the public, and to protect public and private infrastructure.

Blast Specifications

Where possible, blasting at the Integra Open Cut pits is conducted using the nominal blasting

specifications shown in Table 5-1. The specifications may need to be altered to comply with accepted

vibration limits at privately owned houses and public/private infrastructure. The specifications are also

modified for interburden seams less than 9m thick to control flyrock and air blast. The regulatory

limits are discussed in Section 4 of this report.

Table 5-1 Open Cut nominal blasting specifications

Blast hole diameter (range): 147 – 310 mm

Nominally 229 mm

Face height (range): 1.5 - 40m

Stem height (minimum): 1.5 m

No Maximum stemming is set as some

holes may be completely stemmed after

face profiling for Airblast control

Explosive column (range): 0.5- 35m





Face Height (m)

Explosive Charge

mass/m(kg)

Stemming

Height

9 12 15 20

Charge Mass (kg)

ANFO 32.6 4.0 163 260 352 520

HA 1.1 44.0 4.0 220 352 484 704

HA 1.3 53.0 4.0 265 424 583 848

HA = Heavy ANFO (1∙1 - 1∙3 are the specific gravity of the explosives)

Initiation of blasts is made by both electronic, detonating cord and pyrotechnic products. The initiation

timing and direction of each blast is considered on its individual merits to ensure minimised impact to

neighbouring residences and infrastructure.





Figure 5-1 Blast Design Flowchart





5.1.1.2 Ground Vibration

The aim of ground vibration design is the limitation of charge mass to control the ground vibration to

within the regulatory limits for all privately owned houses and private/public infrastructure. The ground

vibration limits are shown in Table 5-2.

The basis of ground vibration design is known as the Scaled Distance Site Law Formula:

PPV =K v

6.1

D

m [1]

Where: PPV = peak particle velocity (mm/s)

m = charge mass/hole (kg)

D = distance (m)

K v =site constant

An essential part of ground vibration control is analysis of measurements and continual review of the

value of Kv used in the design.

The values of Kv have varied considerably because of geological structures such as faults, possible

dykes and sills in the overburden and interburden. A range of Kv from 700 to 4000 has been

experienced in the past. Dulwich Homestead has presented a particular challenge with Kv varying

from 1200 – 4000 with blast vibration transmission direction due to no apparent cause.

The blast specifications to limit ground vibration at the sensitive sites are determined using maximum

charge mass limits derived from the spread sheet model currently used.

The model, with an appropriate Kv factor, is used to determine the maximum charge mass that can be

loaded to limit the PPV levels at all sensitive sites. The maximum charge mass is then converted to a

charge length that is used to design explosive placement and any decking requirement. The loading

for each blasthole in the shot is produced as a loading sheet for the Shot Firing Crew to implement.

Blast specifications to control airblast are generally successful in controlling ground vibration within

regulatory limits. In the case of the Dulwich property, Terrock Engineers have created a spread sheet

blast vibration model to analyse and predict the ground vibration for blasts close to the Dulwich

property to assist in controlling ground vibration levels at Dulwich. This model uses rock mass

transmission properties and blast properties to enable blasts to be designed by charge mass

limitation. Analysis of the blast vibration levels is used for prediction of ground vibration levels after

giving consideration to directional variation of ground characteristics, and initiation sequences and

firing directions.





Ground Vibration Limits

The recommended peak ground vibration levels at the houses and important infrastructure is listed in

Table 5-2.

Table 5-2 Recommended Peak Ground Vibration Levels

ITEM PPV LIMIT REFERENCE

HOUSES

Ground Vibration:

≤ 5mm/s for 95% of blasts in 12 months

≤ 10mm/s for all blasts

(Airblast ≤ 115 dBL for 95% of blasts)

≤ 10mm/s for

all blasts

EPA Environmental Protection

Licence

TD2 & POSSUM SKIN DAM ≤ 10mm/s Dams Safety Committee

UNDERGROUND PORTAL

Normal operations

Portal traffic control required

Damage observation limit

<10mm/s

>10mm/s

25mm/s -

50mm/s

Interim Limit to stop traffic passing

through portal at Blast time.

Other Hunter Valley Mines

Possible Upper Limit

HIGHWALL STABILITY

Damage observation limit

25mm/s -

50mm/s

Interim damage observation limit

Possible Upper limit

CONVEYORS

Without specific investigation

With investigation

50mm/s

100mm/s

Other Hunter Valley mines‟

experience

ENVIROGEN 10mm/s Consult with owners

VENTILATION FANS

External Vibration on Fan Bearings and Rotor

Consult with manufacturers to

determine safe levels before fans

must be shut down

COLLIERY PIT (TOP) 18mm/s BS 7385.2 no damage limit at 10hz

frequency

The structures that will most likely restrict blasting operations, over the life of mine are:

Dulwich Homestead





Cherry House

Possum Skin Dam

Underground Portal and Highwall

Underground Surface Conveyor

ARTC Rail Line and Infrastructure

5.1.1.3 Airblast Overpressure

Airblast from open pit blasting is a pressure wave(s) that is transmitted through the air at the speed of

sound. The airblast is measured as decibels Linear (dBL). Airblast EPL limits are nominated in Table

1-2. The effect of airblast will be minimal at all infrastructure items, including the Underground Portal

and Highwall where human response criteria do not apply. The pressure change due to 120 dBL is

the equivalent change of pressure as a wind gust of approximately 20-28km/hr (5.6 – 7.8 m/s),

described as a moderate breeze that raises dust and loose paper. Air blast of this magnitude has an

equivalent effect on structures to ground vibration PPV levels of about 1 mm/s (ACARP C9040).

Air blast is controlled by confinement of the explosive charge with minimum burden and stemming

height requirements determined from Terrock models. Stemming is inert angular material loaded into

the collar of the drill hole on top of the explosives column to momentarily confine the pressure of the

explosion with the rock mass to prevent premature venting to the atmosphere with accompanying

potential for high airblast, dust and fumes. Rock aggregate of appropriate size and angularity must be

used for effective energy confinement in top of the hole stemming regions within blast holes. .

A typical relationship between airblast and stemming height is demonstrated in Figure 5-2.





Figure 5-2 The sensitivity of airblast to stemming height

The airblast resulting from a blast can be affected by meteorological reinforcement. Under certain

meteorological conditions at the time of a blast, the air blast levels may be increased by up to 20 dBL

at distances beyond about 1 kilometre from a blast. The conditions that may cause this increase are:

Temperature inversion;

Wind speed increasing with altitude; and

Change of wind direction above the surface.

5.1.1.4 Flyrock

The issues with flyrock are:

- the mandatory requirement for stopping traffic on any road for all blasts less than 500m from

the road;

- Blasting protocols for blasting near ARTC rails and infrastructure;

- Exclusion zones for the evacuation of personnel (determination of the exclusion zone will

take into account “line of sight” and ensure a conservative standoff where line of sight

cannot be avoided);





- Safe clearance distance for mobile plant and fixed infrastructure;

- Possible increase in stemming height when blasting near adjoining properties; and

- Statutory reporting of any flyrock that lands outside of the exclusion zone.

In burden controlled conditions, where a free face is available, the maximum throw in front of the face

to a point at the same elevation can be determined using the empirical formula 2, shown below. An

alternative predictive formula, formula 3 shown below, can be applied to determine idealized

stemming heights for confined blasting scenarios.

Lmax=

6.22

8.9

5.13

B

m [2]

Where: Lmax = maximum throw (m)

m = charge mass/meter (kg)

B = minimum front row burden (m)

Lmax = 2.8.9

5.136.22

SinHS

m [3]

Where: S.H = minimum stemming height

= launch angle from the horizontal plus a collar dispersal allowance of 10°

i.e. for vertical holes = 80°

Safety factors are then applied to the maximum throw to assist in planning an exclusion zone, to allow

for:

- the effective burden being reduced by incompetent rock, loose boulders and slabs, cracks

etc.; and

- inadvertent errors during loading.

The safety factors recommended are 2.0 for plant and equipment, and 4.0 for personnel. The

recommended minimum exclusion zone for standard blasts is thereby 80m for plant and equipment

and 160m for personnel.

For blast holes of depths greater than 5 metres, a 5 metre offset from any free faces is adopted to

minimise the risk of fly rock.

In shallow confined blast scenarios, the stemming height must be a minimum of 10 hole diameters.

The shape of the minimum recommended exclusion zone for Open Pit blasts is shown in Figure 5-3.

This is a construction based on the observation that the flyrock throw from a face blast is most likely to

occur in a 90o arc in front of the face, and the throw from stemming controlled blasts is most likely to

occur in a 90o arc behind the face. The two arcs are then connected as shown.





Figure 5-3 Minimum recommended Blast Exclusion Zones

The sensitivity to the maximum throw to stemming height variation is shown in Figure 5-4. As the

stemming height is reduced below 10 hole diameters (2.3m) there is an increased probability that

cratering will occur. If cratering occurs, because of the 45° launch angle, the maximum horizontal

throw increases dramatically. A 500m exclusion zone provides considerably greater protection from

flyrock if the stemming height is inadvertently reduced to about 1.9m and cratering occurs.

Integra has adopted the following conservative Evacuation Zones for its blasting operations:

In front of a face blast (direct line of sight) 500m

Other directions from blasts 300m





For pre-split blasts 150m

The distances may be varied at the discretion of the Drill and Blast Coordinator or Mine Supervisor.

Figure 5-4 The sensitivity of the maximum throw to stemming height

The trajectory paths for flyrock resulting from stemming ejection for different stemming heights are

shown in Figure 5-5. For blasts on benches below the surface, the trajectory profile is modified by the

pit wall, with an effective reduction in horizontal throw behind the face.





Figure 5-5 Stemming ejection/Stemming height relationship

Within the pit, the determination of exclusion zones is the responsibility of the Shotfirer, Drill and Blast

Supervisor and the Manager of Mining Engineering. The maximum throw distance determinations

given herein are intended as a guide to the responsible personnel and do not remove the regulatory

responsibilities from mine personnel.





If blasts are designed with minimum confinement conditions according to the flyrock model, and

checks are set in place during loading, there is sufficient separation from houses and infrastructure

that flyrock will not be an issue. A 500m exclusion zone requiring traffic to be stopped on any road is

very conservative, however may be increased at the instruction of the drill and blast engineer, drill and

blast supervisory personnel or shot personnel to ensure where line of sight presents an increased

likelihood of flyrock damage.

5.1.1.5 Dust and Fumes

A concerted effort is being made at Integra to mitigate the amount of fumes generated from a blast.

Using the Code of Practice developed by the Australian Explosives Industry and Safety Group Inc.

(AEISG), a Blast Fume Management Strategy is attached as Appendix C.

Dust and fumes from blasting can affect the underground ventilation system if carried towards the

mine vent fans following a blast. The shotfirer must ensure that the wind is not blowing towards the

mine fans at the time of the blast. The Drill and Blast Supervisor will be required to consult the mine‟s

weather data system prior to, and up to the time of, the blast and only proceed under favourable

conditions. The wind speed is less important than wind direction. A high wind speed may help to

disperse the dust and fumes. The worst case for dust control is low wind speed with no specific

direction when the plume may drift around for a prolonged period and slowly move towards sensitive

receivers.

For each blast at the design stage the centroid of the blast will be used to determine a Sensitive

Receivers arc for blasting within the South Pit/Western Extension. MGA 56 coordinates and the

ensuing Magnetic Correction will be used to determine this arc. The co-ordinates used for the edges

of this arc are:

E:320606.029 N:6406125.402 R.L:64.558

E:320728.15 N:6404868.159 R.L:86.735

The Magnetic North correction applied is 12.07 degrees

5.1.1.6 ARTC Rail Lines and Infrastructure

Procedure 2029 - Blasting Adjacent to the Main Northern Railway - details the process undertaken by

Integra when blasting activities are undertaken within 500 metres of the Main Northern Railway lines.

Integra has no current intention to blast within 500 metres of the Main Northern Railway Line but

should Integra blast within 500m of the railway line in the future, this procedure will be reviewed and

re-implemented.





5.1.1.7 Road Closure Procedures

Closure of Stoney Creek Road when blasting occurs within 500m of the road is undertaken in

accordance with an annual Singleton Shire Council approval and Procedure 2072, Road Closure -

North Open Cut.

5.1.1.8 Refires or Misfires

Where a misfire occurs the shotfirer will seek to address the misfire and refire as soon as is safely

possible, as per procedure 2034 – Handling Misfires.

Figure 5-6 Open Cut Blasting Flowchart





5.1.2 Design Implementation

The blast is drilled and loaded with the checks and balances outlined and the blast scheduled for

firing according to the Blast Process Flowchart (Figure 5-6). The blasts are duly fired according to the

procedures outlined in Figure 5-6.





An essential component of the blast design is monitoring the environmental outcomes, assessment

and analysis of the results and a review loop to progressively upgrade and refine the predictive

models used in the design, as shown in Figure 5-1.

5.2 POSTPONING A BLAST

Under weather conditions which are likely to result in unacceptable enhancement of blasting impacts

such as elevated overpressure, a blast will be postponed (refer Shotfiring Procedure in Figure 5-6).

5.3 Corrective Measures

The blast design based on appropriate site constants and its correct implementation by the shot firing

crew is usually effective in controlling ground vibration, air blast and flyrock from blasting operations.

The effectiveness of the processes outlined in Figure 5-6 in controlling vibrations to comply with

regulatory limits is determined by the routine compliance monitoring at the monitoring stations.

Observations of flyrock containment and classification of dust and fume behaviour provides a basis for

evaluation of the effectiveness of controlling these emissions.

The assessment of the emissions is part of the blast assessment process and review loops shown

schematically in the Blast Design Procedure in Figure 5-1.

Whenever the air blast readings exceed 115 dBL or the ground vibration readings exceed 5 mm/s at

any monitor, investigations are conducted to ascertain the cause of the elevated reading. When the

air blast reading is in excess of 115 dBL, the following analyses are conducted to establish:

If the high reading was a blast event or some other event, such as wind, by examination of

the wavetrace record for:

- Characteristic air blast wave shape;

- Elapsed time between P wave and air blast arrivals;

- Blast duration; and

- Where in the blast the peak value occurs;

Any visible evidence of high velocity gas emissions by examination of video replay;

The possible effects of wind using regression analysis to compare airblast levels at wind

affected and non-wind affected monitors;

Wavefront reinforcement analysis to determine the possible effects of drill pattern and

initiation sequence; and

Meteorological reinforcement analysis to determine any role of meteorological conditions.

When the ground vibration exceeds 5 mm/s the following analyses are conducted to determine if the

peak value was a form of blast event or some other extraneous vibration source:

Examination of the wavetrace for characteristic wave shape and frequency;

Time of the trigger;





Time of the peak reading relative to the ground vibration arrival; and

Wavefront reinforcement analyses.

The analyses outlined will determine if the peak readings were the blast event or not. If they were

not, predictions can be made of the peak air blast and/or ground vibration. If the peak readings were

from the blast, the section of the blast responsible may be identified and the blast design and loading

reviewed to ascertain the cause. If the elevated air blast levels were due to deficient blast design

and/or loading practices, these can be corrected for future blasts.

Observation and characterisation of fume emissions should lead to a correlation to blasting practice,

and strategies developed for modification that may lead to mitigation.





6. C o m pl a i n t s Ha n d l i n g

Any complaint received relating to blasting issues will be managed in accordance with the

Environmental Management Strategy, which is based on the requirements of the site‟s EPL.

Integra periodically receives complaints/concerns from residents in the surrounding area about blasting issues and building damage concerns either directly or via a government agency. The complaint handling process is demonstrated in Figure 6-1.

All complaints received at Integra are promptly actioned by management and personal contact with the complainant is made as soon as practicable. Where corrective actions are appropriate, these are undertaken.

To overcome the disturbance or 'startling' effect of blasting, a number of residents are notified prior to

each blast.





Figure 6-1 Complaint management process flow chart





7. R e p or t i n g a n d R e v i ew

7.1 Reporting

Ground vibration and air blast readings in excess of the 10 mm/s / 120 dB(L) limit must be reported

immediately to both the EPA and Department of Planning & Infrastructure (DP&I) followed by a report

of the investigation into the causes of the exceedence.

Blast results and interpretations will be reported internally after each blast, summarised monthly and

included in the Annual Report (AR).

The Monthly and Annual reports will include:

- No. of blasts fired

- No. of vibration measurements at each monitoring station

- No. of blasts 5 mm/s

115 dBL

- No. of exceedences 10 mm/s

120 dBL

The AR will provide a summary of complaints, the concerns and complaints received, plan showing

the complaint locations and remedial action taken.

A copy of the AR will be forwarded to relevant stakeholders including, but not limited to, Department

of Trade and Investment, Regional Infrastructure and Services (DTIRIS) NSW EPA and DP&I.

Integra is reviewing the presentation of monitoring data it has collected and analysed on its website,

with the intention of making the site more informative and user-friendly from a community perspective.

It is anticipated that the review will be completed by June 30, 2012.

7.2 Plan Reviews

The review of this document will be in line with the Environmental Management Strategy for the

Complex. That is, reviews will be conducted every three years, after independent environmental

audits, and as required by relevant Project Approval requirements. The purpose of the review is to

ensure that the BMP remains suitable, adequate and effective.

The monitoring data will be reviewed as it is collected and at strategic milestones in the mine life,

including annual (AR) reporting periods. The BMP will be modified as required to reflect changes to

mine plans, monitoring results or in response to stakeholder comments. Any modifications will be

made in consultation with OEH and approved by the DP&I.





8. R e f er e n ce s

Australian Coal Association Research Project (2002), Project C9040, “Structure Response to Blast

Vibration”

Integra Mine Complex Project Approval 08_0101 and 08_0102, dated 26 November 2010.

Integra Coal Operations Pty Ltd Environmental Protection Licence (#3390)

Integra Explosives Hazard Management Plan (HMP_2001)

Integra Road Closure Procedure – North Open Cut (PRO_2072)





9. G l o s sar y

TERM DEFINITION

AEISG Australian Explosive Industry and Safety Group (Inc)

ARTC Australian Rail Track Corporation

Authorised Person OC

Person appointed in writing by the Open Cut Mine Manager to carry out

specific duties under the Shotfiring and Explosives Management

System.

Approved

Has the meaning in the Coal Mines Regulation Act 1982

(Approved by the Chief Inspector. This could apply to use of non-

permitted explosives)

Blasting Operations Include:

- Priming a cartridge;

- Charging and stemming a hole;

- Connecting the detonator into a round of shots;

- Coupling a shotfiring cable or lead-in line into a detonator circuit,

circuit tester or exploder;

- Testing a shotfiring circuit; or

- Firing a shot or round of shots

Burden The distance between a blast hole and a free face, or the distance

between rows of holes in a blast pattern.

Competent Person (CP) Person appointed in writing by the Open Cut Mine Manager to carry out

specific duties under the Shotfiring and Explosives Management

System.

Danger Zone An area in which a person may be injured or machinery may sustain

damage as a result of shot firing activities.

Exploder Any electrical apparatus approved for the purpose of initiating

detonators in a mine.

Explosive Includes detonation cord, detonators, relays, signal tubes, signal tube

starters, primed cartridge or similar devices.

ICOL Integra Coal Operations Pty Ltd

ICU Integra Underground





Misfire An occurrence where:

- Testing before firing a shot reveals broken continuity which cannot be

rectified; or

- Any shot, or whole or part of a round, fails to explode when an attempt

is made to fire it.

Shot A charge of explosive (in a cartridge) placed in a shot hole in coal or

other rock (or stone) for the purpose of breaking the coal or rock (or

Stone).

Shotfirer A person appointed by Mine Management to conduct shotfiring as part

of the Shotfiring and Explosives Management System.

Spacing The distance between holes in a row of holes in a blast pattern.

Stemming Height The appropriate length of stemming material loaded on top of the

explosive column in a blast hole to control fly rock and limit air blast.

Stemming Material Inert coarse material, such as crushed gravel about 1/10th hole diameter,

loaded into the blast hole to confine the gaseous energy and prevent it

from venting into the atmosphere.

Underground Sentry Person appointed competent by the underground mine manager to act

as a sentry for the underground during shot firing.

Underground Surface The area in which the Underground mine manager is statutorily

responsible.

Underground Surface

Attendant

Person trained and appointed competent by the underground mine

manager to carry out all required surface duties.

Underground Workings All workings underground accessed from the Underground pit portals.

The Underground mine manager is statutorily responsible for this area.





APPENDIX A - APPROVAL CONDITIONS AND EA COMMITMENTS

Table A1 Approval Conditions and EA Commitments – Where They Are Addressed in the BMP

Approval Condition BMP Reference

Blasting Criteria

11. The Proponent shall ensure that the blasting on site does not cause exceedances of the criteria in Table 9 (below).

Receiver Airblast Overpressure (db(Lin Peak))

Ground Vibration (ppv(mm/s))

Allowable Exceedance

Residence on privately-owned land

115 5 5% of the total number of blasts over a period of 12 months

120 10

Main Northern Railway culverts and bridges

- 25 0%

All public infrastructure

- 50 0%

However, these criteria do not apply if the Proponent has a written agreement with the relevant landowner or infrastructure owner to exceed the criteria, and the Proponent has advised the Department in writing of the terms of this agreement.

1.4 (p. 6)

5.1.1.2, Table

1-2(p.19)

Blasting Hours

12. The Proponent shall only carry out blasting on site between 9am and 5pm Monday to Saturday inclusive. No blasting is allowed on Sundays, public holidays, or at any other time without the written approval of the Director-General.

1.4 (p. 6)

Blasting Frequency

13. The Proponent shall not carry out more than:

(a) 1 blast a day in the northern mining area unless an additional blast is required following a blast misfire;

(b) 2 blasts a day in the existing Camberwell south pit, and then 1 blast a day when the mining moves from this pit into the western mining area unless an additional blast is required following a blast misfire; and

(c) 10 blasts a week on site, averaged over any 12 month period.

1.4 (p. 6)

Property Inspections

14. If the Proponent receives a written request from the owner of any privately-owned land within 2 kilometres of the approved open cut mining pits on site for a property inspection to establish the baseline condition of any buildings and/or structures on his/her land. Or to have a previous property inspection report

1.4 (p. 8-9)





updated, then within 2 months of receiving this request the Proponent shall:

(a) commission a suitably qualified, experienced and independent person, whose appointment has been approved by the Director-General to:

• establish the baseline condition of the buildings and/or structures on the land or update the previous property inspection report; and

• identify any measures that should be implemented to minimise the potential blasting impacts of the projects on these buildings and/or structures; and

(b) give the landowner a copy of the new or updated property inspection report.

Property Investigations

15. If any landowner of privately-owned land within 2 kilometres of any approved open cut mining pit on site claims that the buildings and/or structures on his/her land have been damaged as a result of blasting on site, then within 2 months of receiving this request the Proponent shall:

(a) commission a suitably qualified, experienced and independent person, whose appointment has been approved by the Director-General, to investigate the claim; and

(b) give the landowner a copy of the property investigation report.

If this independent property investigation confirms the landowner's claim, and both parties agree with these findings, then the Proponent shall repair the damages to the satisfaction of the Director-General.

If the Proponent or landowner disagrees with the findings of the independent property investigation, then either party may refer the matter to the Director-General for resolution.

1.4 (p. 8-9)

Operating Conditions

16. The Proponent shall:

(a) implement best blasting management practice on site to:

• protect the safety of people and livestock in the surrounding area;

• protect private or public property in the surrounding area;

• minimise the dust and fume emissions of the blasting; and

(b) co-ordinate the blasting on site with the blasting at nearby mines (including Ashton, Rix‟s Creek and Mt Owen mine) to minimise the cumulative blasting impacts of the mines;

(c operate a suitable system to enable the public to get up-to-date information on the proposed blasting schedule on site,

to the satisfaction of the Director-General.

17. The Proponent shall not undertake blasting within 500 metres of:

(a) Middle Falbrook Road or Stony Creek Road without the approval of Council;

(b) the New England Highway without the approval of the RMS; and(c) the Main Northern Railway without the approval of the ARTC.

18. The Proponent shall not carry out blasting in the northern or western mining areas that is within 500 metres of any privately-owned land or land not owned by the Proponent unless:

(a) the Proponent has a written agreement with the relevant landowner to allow

1.4 (p. 8-9)





blasting to be carried out closer to the land, and the Proponent has advised the Department in writing of the terms of this agreement; or

(b) the Proponent has:

• demonstrated to the satisfaction of the Director-General that the blasting can be carried out without compromising the safety of the people or livestock on the land, or damaging the buildings and/or structures on the land; and

• updated the Blast Management Plan to include the specific measures that would be implemented while blasting is being carried out within 500 metres of the land.

Blast Management Plan

19. The Proponent shall prepare and implement a Blast Management Plan for the open cut mining operations on site to the satisfaction of the Director-General. This plan must:

(a) be prepared in consultation with DECCW, and submitted to the Director-General for approval by the end of March 2011;

(b) describe the blast mitigation measures that would be implemented to ensure compliance with the relevant condition of this approval;

(c) describe the measures that would be implemented to ensure that the public can get up-to-date information on the proposed blasting schedule on site;

(d) include a blast monitoring program to evaluate the performance of the project; and

(e) include a protocol that has been prepared in consultation with the owners of the nearby mines for minimising and managing the cumulative blasting impacts of the mines.

1.4 (p. 8-9)

EA Commitments BMP

Reference

G8 Continued implementation of the existing Explosive Hazard Management Plan to ensure the safety of employees and the public during explosives handling and blasting operations

Refer to Integra

Explosives Hazard

Management Plan

G9 Restrict blasting to between the hours of 9.00am and 5.00pm Monday to Saturday, unless blasts outside this time are required for misfire re-blast, emergency or safety reasons.

1.4 (p. 8)

G10 Blast design and implementation to be undertaken by a suitably qualified blasting engineer and/or experienced shot-firer to ensure ANZEC Guidelines are met at all non-project related residences surrounding the Open Cut Project Area.

Table 3-1(pp. 12-

13); Table 5-1(p.16)

G11 Refine blast mitigation measures and operating procedures as required based on monitoring results.

5.3 (p. 30)

G12 Provide notification on the morning prior to a blast of blast times to local residents and others who request to be included on the notification list.

5.1, Table 3-1(p.

16)

G13 Use aggregate as the stemminq material (not drill dust) in order to fully contain the explosives within the blasthole.

5.1.1.3 (p.21)

G14 In the case of the Part Pit Extent (ie. Integra is unable to acquire Residence Conditions for





153 or negotiate an agreement with the owner) blasting will not be undertaken within a 500m Exclusion Zone surrounding the 'Dulwich' residence and 200m from the property boundary until such time that it can demonstrate to the Director-General that blasting can be undertaken without an unacceptable risk to the resident, residents, their stock or residence.

Western

Extension

Blast Fume Management Strategy FRM-XXXX




APPENDIX B - UNDERGROUND TARP

TRIGGER ACTION/PROCEDURE

Blast location with:

- Vibration predicted to be less than 10mm/s at

portals.

Mining operations normal


- Wind blowing from blast location towards U/G

portals, and/or

- Vibration predicted to be greater than

10mm/sec at portals

Evacuation for shot duration procedure

Evacuate surface personnel


- Wind blowing from blast location away from

U/G portals, and

- Vibration is predicted to be greater than

10mm/sec at portals.

Procedure to remain underground during shot with portal access control

Evacuate surface personnel





APPENDIX C – INTEGRA COAL OPEN CUT: BLAST FUME MANAGEMENT STRATEGY

INTRODUCTION:

This document has been prepared in response to the NSW Department of Planning and Infrastructure’s directive for a Blast Fume Management Strategy to be developed on site, and incorporated into the Blast Management Plan for Integra Coal.

The purpose of the Blast Fume Management Strategy is threefold:

Provide a protocol to minimise fume emissions

Rate and record all blast fume events

Reporting of significant fume events

Blast Fume:

All blasting explosives produce large volumes of gas in very short time frames. Blast fume is identified by plumes of cloud that vary from yellow to dark red in colour. This is caused by the production of nitrogen dioxide, and the oxidation of nitric oxide, which is chemically unstable in air. Multiple causes have been identified that compromise the explosive reaction resulting in the production of nitric oxide (NO) and nitrogen dioxide (NO2).

Potential causes of fume in blasting:

Fume is generated as a result of an explosive not reacting to its full capability through a high order, steady state of detonation. The causes of this are varied, however the seven main reasons for fume generation as accepted by the industry and explosive suppliers are listed below:

Geological conditions

Weather conditions

Blast design parameters

Explosive product selection

Explosive quality

Downhole contamination of the explosive product

On bench practices





INTEGRA PERSONNEL AND THEIR ROLES:

This section identifies the persons within the Integra Coal Pty Ltd (Integra) organisation and their responsibilities in relation to ensuring the prevention and minimisation of fume generation. These roles are:

1. Planning Engineers

2. Geologists

3. Drill & Blast Engineer

4. Technical Services Superintendent

5. Drill & Blast Superintendent

6. Driller

7. Shotfirer (Blast crew member)

8. Bulk Explosives Vehicle operator

9. Explosive manufacturer / supplier

Planning Engineers:

Planning engineers are responsible for the sequence of mining operations.

Planning Engineers are to consider:

Shot relief, and the minimisation of confined blasts

Geologist:

Provide relevant data on geological conditions.

Geologists are to consider:

Weak strata

Weathered zones

Reactive ground

Hot coals





Drill & Blast Engineer:

Design the blast areas to provide safe and productive extraction of the blasted material.

Drill and Blast Engineer is to consider:

Geology and rock mass conditions

Explosive product selection appropriate to the ground conditions

Historical blast performance

Weather conditions during the planned loading & firing phase

Shot relief

Water / moisture content of strata

Initiation (timing) sequence

Compliance to operational consent conditions

The Drill & Blast Engineer, Technical Services Superintendent and the Drill & Blast Superintendent will jointly approve the blast design.

Technical Services Superintendent:

Review the design of blast areas provided by the Drill & Blast engineer.

Responsibilities include:

Ensure all design parameters as above, have been considered to mitigate production, environmental and legislative hazards

Assume or delegate the responsibilities of the Drill and Blast Engineer in their absence

Jointly approving blast designs with the Drill & Blast Superintendent and Drill & Blast Engineer.

Drill & Blast Superintendent:

Manage all Drill and Blast operations for the site.


Ensure competence of the Drill & Blast Team to perform their duties





Adequate resourcing of persons and plant to complete blasting activities in a timely manner

Ensure industry best practice is employed in the implementation of blast designs to mitigate all potential production, environmental and legislative hazards

Jointly approving blast designs with the Technical Services Superintendent and the Drill & Blast Engineer.

Supervise all Drill and Blast on bench activities for the site.

Bench preparation prior to drilling

Conduit between drill activity and engineer to ensure all relevant information is communicated for consideration in design

On bench water management

Review the product selection to ensure appropriate for ground and weather conditions

Ensure on bench compliance to design during implementation process

Manage stemming delivery to eliminate contaminants

Film each blast, or nominate a delegate to film each blast

Driller Operators

To provide drilled holes for the loading of explosives for a blast area.


Accurately drill the designed blast plan and report / record all variations

Report anomalous ground conditions to the supervisor

Emplacement of collar protection for drilled holes

Record all required information

Shotfirer (Blast Crew Member):

Conduct and direct all blasting activities on bench.






Compliance with design

Notify and record any variations from design

Record explosive usage data

Supervision of loading – prevention of contamination to explosive

Accurate placement of gas / air bags / decks as per design

Manage on bench Bulk Explosives Vehicle activities / movement

Measure the depth of blastholes

Ensure quality control of bulk explosive by on bench tests

Identify, report and record water conditions down hole

Correctly position primers within explosive

Report and record blasthole slumping

Information conduit between on bench activities and Supervisor

Supervision of stemming process to ensure sufficient containment and no contamination of material

Report and record all anomalies during process

Bulk Explosive Vehicle Operator:

Manufacture and downhole delivery of explosive. Assist with on bench activities as directed by Shotfirer or Supervisor.


Compliance with design and Shotfirers instructions through loading process

Bulk Explosives Vehicle calibration

Ensure quality control of all delivered products

Record explosive delivery usage by blast hole & blast area





Explosive Manufacturer / Supplier:

All explosives, precursors and accessories supplied are fit for purpose and certified as per ISO 9000: 2008.


Manufacturing equipment compliance

Ensure competence of personnel

Provide recommendations for product usage and training as required

Ensure the design, calibration and operation of Bulk Explosives Vehicle is such to deliver consistent explosives within specification

Provision of explosive and precursor formulation to ensure minimisation of fume from product





POTENTIAL CAUSES OF FUME GENERATION AND MITIGATION CONTROLS

This section details the key potential causes of blast fume and their controls.

GEOLOGICAL CONDITIONS

Potential Cause

Weak or soft strata, including clay

Controls:

Understand the geology prior to loading and initiation sequence design to ensure correct explosive product used (refer explosive suppliers recommendations) and adequate relief through modified timing and reduction of powder factor

Potential Cause:

Loss of explosive product, not achieving designed collar height – faulted / fractured ground

Controls:

Manufacturer’s recommendations of explosive product selection.

Record and monitor loaded blast holes that have slumped or required additional explosive to achieve design collar height.

Use of blast hole liners

Potential Cause:

Dynamic water in blast holes

Controls:

Follow manufacturer’s recommendations of explosive product selection.

Minimise sleep time; blasting practices are designed to achieve a maximum load, tie

and fire time of 7 days in accordance with Site Management Directive.

Consider use of blast hole liners.





WEATHER CONDITIONS

Potential Cause:

Rainfall or flooding resulting in the ingress of water into the explosive column

Controls:

Review weather forecast prior to product selection

Bench preparation to allow for water run-off

Follow manufacturers recommendations of explosive product selection



Consider initiating all loaded holes prior to severe storm events

BLAST DESIGN

Potential Cause:

Desensitisation of explosive product

Controls:


Reduce explosive column length

Potential Cause:

Interaction of decked blast holes

Controls:

Review actual drilled holes and amend design (timing) to reflect

Ensure appropriate timing delays between decks

Use electronic initiators to ensure accurate, reliable initiation





Potential Cause:

Excessive confinement, incorrect timing and pattern geometry design.

Controls:

Understand geology of the blast area and design to mitigate hazards

Consider use of free face to reduce confinement

Reduce powder factor

Utilise timing to ensure adequate relief for all strata

EXPLOSIVE PRODUCT SELECTION

Potential Cause:

Non-water resistant explosive products loaded into wet or dewatered blast holes

Controls:


Regular training of blast crew on explosive product recommendations from supplier

Correct loading technique used when loading wet holes

Potential Cause:

Excessive energy in weak / soft strata that desensitises adjacent explosive product columns

Controls:


Understand geology of the blast area and design (timing & explosive type) to mitigate hazards





EXPLOSIVE QUALITY

Potential Cause:

Inadequate mixing of raw materials that leads to incorrect explosive formulation

Controls:

Explosives formulated by supplier to an appropriate oxygen balance that reduces risk of fume generation

Regular Bulk Explosives Vehicle calibration

On bench quality control checks

Potential Cause:

Explosive precursors, bulk materials and explosive accessories not manufactured or supplied to specification or degradation occurs during transport, storage or extended sleep time (time explosive is in hole)

Controls:

Contractor supplies certification of delivered products – ISO9000: 2008.

Regular audits to ensure quality control compliance

Control blast size and loading plan to minimize the sleep time; blasting practices are

designed to achieve a maximum load, tie and fire time of 7 days in accordance with Site Management Directive.


Potential Cause:

Inaccurate explosive product delivery through defective metering system

Controls:

Regular audits to ensure quality control compliance

Regular Bulk Explosives Vehicle calibration

On bench quality control checks





CONTAMINATION OF EXPLOSIVES IN THE BLASTHOLE

Potential Cause:

Explosive product mixes with mud / sediment at bottom of blast hole, realised when measured depth varies from drilled depth

Controls:

Drill procedures to minimise blast hole damage

Ensure correct blast hole priming and loading procedures are followed on bench

Where contaminants are identified at the blast hole bottom use a gas bag to separate mud from explosive product

Potential Cause:

Stemming material penetrates explosive product

Controls:

Ensure pumped product (slurry) is properly gassed, to suppliers specifications, prior to stemming process

Use only appropriate stemming material

Potential Cause:

Water entrainment in explosive product – dewatered blast hole, dynamic water present

Controls:

Load wet / dewatered blast holes first and check other holes around for water ingress through displacement

Ensure appropriate blast hole priming and loading practices (place primer in undamaged explosive product) are followed on bench


Do not “top load” into wet or dewatered blast holes

Protect top of explosive column to prevent water ingress e.g. gas bag







ON BENCH PRACTICES

Potential Cause:

Blast pattern not drilled to design and holes unable to be identified

Controls:

High precision (GPS) used on drill rigs

Optimise drilling practices to ensure accurate hole depths achieved

Potential Cause:

Blasthole incorrectly identified, incorrect explosive product used

Controls:

Load sheets are given for each hole

Assess all blast hole conditions prior to loading

Potential Cause:

Dewatering of blast holes diverts water into previously loaded (with dry hole product) holes

Controls:

Load wet / dewatered blast holes first and check other holes around for water ingress through displacement

Bench preparation to allow for water run-off





RATING AND RECORDING OF BLAST FUME EVENTS

RECORDING OF FUME EVENTS

Every blast initiated at the Integra Mine Complex is to have its fume rated and recorded as per the current edition of the Australian Explosives Industry and Safety Group Inc code of practice titled “Prevention and Management of Blast Generated NOx Gases in Surface Blasting” (the “AEISG Code”). The fume must be rated at its greatest extent. Fume rating records must be kept onsite for a minimum of two years.

Each blast initiated at the Integra Mine Complex will be filmed. Where safe, the filming will be undertaken by a person on site. If considered unsafe, the camera will be unattended. Video footage must be stored for a minimum of 1 year. Video records of fume will ideally continue for a minimum of one minute after the blast event and capture any post blast fume until it dissipates.

REPORTING OF SIGNIFICANT FUME EVENTS TO THE DEPARTMENT

Integra will notify the Department of Planning and Infrastructure compliance officer in Singleton of any blast producing post blast fume that rates 3 at its highest extent and leaves the mine site and any blast that rates 4 or 5. The mine site includes any area within the active Project Approval boundary and any closed portion of public road.

When post blast fume reports are required, the quantity of explosive and the number of blast holes should be included. The purpose of this is to provide a guide to size the fume event. Not all blasts required to be reported will require a formal incident report, as this will depend on a number of factors and will be determined after consultation with the Department of Planning and Infrastructure compliance officer, in accordance with the Integra Coal Pollution Incident Response Management Plan (EMP_2014).

DUTY TO REPORT POLLUTION INCIDENTS

Additional reporting obligations apply to post blast fume events if they meet the definition of a pollution incident as listed in the Integra Coal Pollution Incident Response Management Plan (EMP_2014): A pollution incident is required to be notified if there is a risk of ‘material harm to the environment’, which is defined in Section 147 of the Protection of the Environment Operations Act 1997 as: (a) harm to the environment is material if: • it involves actual or potential harm to the health or safety of human beings or to ecosystems that is not trivial, or • it results in actual or potential loss of property damage of an amount, or amounts in aggregate, exceeding $10,000 (or such other amount as is prescribed by the regulations), and (b) loss includes the reasonable costs and expenses that would be incurred in taking all reasonable and practicable measures to prevent, mitigate or make good harm to the





environment. A pollution incident must be reported immediately to the EPA, NSW Health, Fire and Rescue NSW, WorkCover NSW and Singleton Shire Council, the NSW Department of Planning & Infrastructure and the Division of Resources & Energy of the Department of Trade & Investment. Regional Infrastructure & Services should also be informed.

REQUIRED RECORDS AND DOCUMENTATION:

The records and documentation used for the design, bench preparation, drilling, loading and firing of a blast area are retained in the Technical Services office by the Drill & Blast Engineer. The records, contents and those responsible are:

Design and Pre-Loading Checklist (FRM_2520)

Responsible persons:

Drill & Blast Engineer

Drill & Blast Supervisor

Surveyor

Contents:

Blast pattern parameters – geometry, depth, hole diameter

Geological considerations – rock type, exploratory holes, model information

Powder Factor

Maximum Instantaneous Charge Weight (MIC)

Laser profile of free faces

Road closure required

Tie up considerations – vibration, overpressure, relief

Bench preparation – survey pegs, clean up, accesses

Drill information (down hole strata-log)

Any / all anomalies





Shotfirers Loading Checklist (FRM_2092)


Shotfirer

Stemming Operator

Contents:

Shotfirer in charge of blast area nomination

Loading practices – explosive type, charge weights, stem heights

Blast hole condition and consideration – wet, redrills required, pre-conditioned collars

Contamination of delivered stemming material

Stemming of blast holes – all blast holes stemmed, all irregularities noted

Explosive Used Register (FRM_2683)


Shotfirer

Bulk Explosives Vehicle Operator

Contents:

Shot number and date of loading

Explosive type and quantity used

Shotfirers Tie & Fire Checklist (FRM_2092)



Shotfirer

Drill & Blast supervisor





Contents:

Ensure Initiation sequence is appropriate

Tied in according to design / plan

Environmental considerations - wind speed, wind direction, inversion, cloud cover

Notification requirements complete – blast board, workforce, community

Sentry positions decided

Video in place – video footage is continued after blast detonation to ascertain actual fume / dust generation, direction travelled and dispersion rate

Explosives returned to magazine

Check monitor results for environmental compliance

Explosive and Accessory Loss and Gain Register (FRM_2567)


Shotfirer

Bulk Explosives Vehicle Operator

Contents:

Shot number and date of loading

Explosive type and quantity used

Comments on any / all variations

Environment and Community Blasting Considerations (FRM_2440)




Tech Services Superintendent

Contents:





Wind effects – direction / speed

Potential community impacts

Potential dust / fume generation

Approval to detonate blast area

Actual blast results – wind speed and direction, fume rating (based on Orica scale)

Shotfirers Report


Shotfirer

Contents:

Shot Number

Location of blast

Shotfirer in charge

Pattern Size

Blast hole diameter

Number of blast holes

Average depth

Number of wet blast holes

Date / time of firing

Blast volume

Actual Powder Factor

Down hole explosives used – type & quantity

Explosive accessories used – type & quantity

Initiation sequence





Actual environmental conditions at time of firing – wind speed and direction, cloud cover, inversion, buffered blast area

Blast results – fume generation, misfired holes, flyrock distance, fragmentation

Sign off on completion of blast

Drillers Information sheet


Driller


Contents:

Shot Number – modular description

Location of blast

Pattern Size (burden & spacing)

Blast hole diameter (drill bit size)

Number of blast holes

Depth of holes

Down hole strata logs

Comments on any / all anomalies

REFERENCES

Integra Coal Explosive Hazard Management Plan (HMP_2001)

Integra Open Cut Blast Management Plan

Bulk Explosives Supplier - Product Selection Guide- Technical Data Sheets

- Product Compatibility Sheets

- Fume Self Assessment Guide

Integra Coal Drill & Blast Study – November 2010





Pollution Incident Response Management Plan (EMP_2014)

AEISG Code of Practice for Management of Post Blast NOx Fume in Surface Blasting

Queensland Guidance Note 19 – Management of Oxides and Nitrogen in Open Cut Blast (QGN19v1 6 Jun11)

Department of Planning & Infrastructure Guideline Attachment 1: Elements of a Blast Fume Management Strategy

blast management plan 2012 2015 -...

Documents