Tag Archives: mine safety

OndoSense introduces compact radar sensor for collision avoidance, vehicle detection and object positioning

Automation, Communications in mining, IoT, Mining safety, , , ,

OndoSense is expanding its sensor portfolio with the addition of a compact radar sensor for collision avoidance, vehicle detection and object positioning.

With its wide detection range, the OndoSense reach WA (Wide Angle) is particularly suited for detecting obstacles such as vehicles, people or objects. It detects static and moving objects, even at close range from 0.1 m, and can be easily integrated even in confined spaces, thanks to its very small design, the company claims.

The OndoSense reach WA is suitable for collision avoidance, vehicle detection, object positioning and limit level control in transport & logistics, mining, shipping, mechanical and plant engineering and agriculture, it added.

With up to four adjustable sensor zones, the OndoSense reach WA is ideal for flexible monitoring of security areas or collision avoidance of mobile robots or other vehicles. Thanks to innovative radar technology, the radar sensor always reliably detects objects of any nature, even difficult environments with dirt, smoke, steam, rain or poor lighting conditions. And, as a result of its high measuring rate of 200 Hz, it always reliably detects obstacles even with fast movements.

Rainer Waltersbacher, co-CEO of OndoSense, said: “Our sensor offers the smallest blind zone on the market for anti-collision radars. This makes the OndoSense reach WA ideal for applications in which objects in close range must be reliably detected. Our radar system thus enables safe operation without costly unplanned downtimes.”

With its M30 design and a length of just 92 mm, the OndoSense reach WA is one of the smallest radar sensors for collision protection & object positioning, OndoSense says. Thanks to an opening angle of 15° and a measuring precision of ±1 mm, the OndoSense reach WA is suitable for precise positioning of machines or robot arms where the target object is tilted – i.e not optimally aligned with the radar sensor.

The radar sensor has an RS485 communication protocol, three digital switching outputs (PNP/NPN) and an analog current interface (4-20 mA). An IO-Link version will be available from 2025. The sensor can operate interfaces such as Profinet or CAN via a gateway.

Best practices for selecting onboard fire suppression systems for heavy-duty mining vehicles

Environmental, Mining safety, Mining services, Sustainable mining, , , , , ,

Heavy-duty mining vehicles operate for long periods across harsh, rugged environments and require reliable onboard fire protection to help protect people, equipment and the business continuity of the mine. However, as mining vehicles continue to become larger, more powerful and more complex, their fire hazards have changed, too. Most mining vehicles have multiple fire hazards that could require application-specific fire protection solutions. By protecting each hazard with the appropriate on board fire suppression system, the damage to the equipment is limited and operator safety is improved in the event of a fire, Kristin Ryczek* says.

When selecting hazard-specific onboard fire suppression, it’s important to consider several factors for best results. Here are six best practices to follow:

1. Understand the fire risks that are present

The first step to selecting onboard fire suppression systems is understanding the specific fire risks on mining equipment. By clearly understanding the risks that are present, mining companies can equip their vehicles with the most effective fire suppression solution for each fire risk. Electrical hazards, for example, necessitate a different approach to fire suppression than what is required for engine compartments.

The engine compartments in many of today’s mining vehicles contain turbocharger exhaust manifolds and emission packages, as well as diesel fuel sources, hydraulic fluid and other class B fuels. The engine components are likely to have high surface temperatures that can create an ignition source. For engine component protection, it’s important to seek a solution that can cool superheated surfaces while providing comprehensive suppression capabilities. Using the right solution makes fire suppression efforts more effective while minimising the risk of reignition.

Powered cables can also be an ignition source for the hydrocarbons that are within the engine and hydraulics if not properly maintained. However, electrical equipment, which is often stored inside unoccupied cabinets, requires different fire suppression considerations. This equipment is often more sensitive than engine compartments, and failure due to fire or smoldering can lead to significant operational disruptions. For this application, it’s often best to consider an electrically non-conductive clean agent solution designed to suppress fire without damaging electronics. Clean agent systems will often use a nitrogen agent, which requires no clean-up and has a zero global warming potential (0 GWP), making it a good option for equipment and the planet.

2. Consider single-agent vs. dual-agent solutions

For several decades, heavy mining vehicles have depended on dual-agent fire protection systems for their engine compartments. As the name suggests, dual-agent (or twin-agent) systems use both dry chemical and liquid agents in a single design. The dry chemical agent rapidly knocks down flames, and the liquid agent cools hot surfaces and minimises reflash potential. However, the suppression benefits these dual-agent configurations provide come with additional complexity – including costly clean-up and repairs after a dry chemical discharge, careful planning for side-by-side installations and the need to activate two separate systems simultaneously.

These challenges emphasise the need for new fire suppression solutions that simplify fire protection while meeting the needs of today’s heavy-duty industrial vehicle operations. While some mining vehicle applications require twin-agent systems to meet the NFPA 120 and 122 standards, the latest single-agent systems hold FM approval and are suitable for many applications. Single-agent systems can streamline the complexities of dual-agent systems, and some superior single-agent options can even provide higher-performing and more cost-effective fire protection for mining vehicles than traditional dual-agent systems.

3. Look for solutions designed specifically for your needs

When protecting multiple vehicle hazards with unique fire suppression needs, it’s important to choose solutions that have been designed specifically for those applications. Application-specific design helps ensure more effective system performance and efficient installation and maintenance. This is especially relevant in the mining industry where products need to be built to withstand long hours in extremely harsh conditions. Effective fire suppression system design is achieved through a deep understanding of the risks, the assets being protected and the ideal amount of agent that needs to be discharged onto the hazard.

When protecting engine compartments, application-specific fire suppression solutions can offer increased operational flexibility and simplicity. This is due in part to recent liquid single-agent advancements that allow each nozzle to cover more area – up to 54 in (137 mm) – compared with previous dual-agent solutions. This extended spray distance helps the agent flow into hard-to-reach areas where flammable liquids may have migrated. It also allows end users to select and install the ideal number of nozzles for their applications. Fewer nozzles generally mean less installation and maintenance needs for the end user. That’s because less nozzles mean less hose network to route through the hazard. Less agent and less tanks also mean less weight added to the vehicle for overall efficiency.

There are also benefits to selecting an application-specific fire suppression solution for electrical enclosures. Some nitrogen-based systems designed for mining vehicles don’t require many of the safety devices that a carbon dioxide system would require, including time delays and lockouts. This translates into less components to install and maintain. Some nitrogen-based systems also have a wide temperature operating range to withstand extreme conditions. Users should look for solutions with an operating range of -65° F to plus 210° F (-54°C to plus 99°C) and with a rugged design to help ensure effective use in the harshest environments.

4. Look for solutions that have been rigorously tested and/or hold third-party approvals

When it comes to fire suppression in extreme mining environments, bold claims are not enough. It is critical that fire suppression agents for mining vehicles are backed by rigorous testing and third-party approvals, such as FM approval.

Johnson Controls recently conducted extensive testing to prove effectiveness of a new, non-fluorinated single-agent liquid system. The company wanted to prove it can prevent reflash by quickly knocking down flames, blanketing the fuel and cutting off oxygen without the addition of a dry chemical agent. The team evaluated the new agent (ANSUL® LVS NF-40) against some of the leading single-agent and twin-agent setups currently used in the industry.

The testing results confirm the standalone performance of the new liquid agent. It demonstrates the speed at which the new liquid agent can extinguish high-pressure fuel sprays and fuel in-depth pool fires while also cooling the entire mass of the plate and the fuel in-depth pan below. Additionally, the new liquid agent had a lower discharge time than the tested legacy liquid agent, which demonstrated that less of the new liquid single agent is required for effective fire suppression.

5. Consider regulations and standards, as well as environmental impacts and sustainability

In many industries, including mining, regulations are shifting around the use of per- and polyfluoroalkyl substances (PFAS). Because of these changes, the mining industry is moving toward non-fluorinated fire suppression solutions for mining vehicles. When selecting a non-fluorinated onboard solution for effective Class A and B fire suppression on mobile mining equipment, it is important to choose a non-fluorinated agent that offers performance equal to or better than previous formulations.

NFPA 122, the standard for fire prevention and control in metal and non-metal mining and metal mineral processing, requires the use of a twin-agent suppression system in ultra- and mega-class mining equipment with hydraulic systems containing more than 150 gallons (682 litres) in the lines. However, there are now single-agent fire suppression systems that have been tested and received FM 5970 approval to perform just as well as twin-agent systems.

While NFPA standards are often used as guidance for enforcement of the required fire suppression by Authorities Having Jurisdiction (AHJ), they aren’t always the only accepted method for providing fire suppression. Standards like NFPA often take time to update and change as the market and available solutions evolve. A white paper from Johnson Controls provides supporting data and evidence that could be used by an installer or end user making the case to a notified body to accept an effective single-agent system over the twin-agent system that NFPA suggests. As such, an installer or end user could apply an FM 5970-approved single-agent system, acknowledging the need for conversation with any AHJ to approve the installed system. As the fire industry progresses, it’s possible that standards will update and become aligned with newer, more fit-for-purpose solutions.

For electrical compartments in mining vehicles, it’s important to source a clean agent that meets stringent government regulations surrounding chemical agents. From an environmental and regulatory standpoint, a nitrogen-based clean agent may be preferable over clean agents with a chemical formulation and can simplify compliance processes. Nitrogen has been a popular clean agent gaseous suppression option for many years, since it is a naturally occurring atmospheric gas and does not fall under restrictive regulatory measures. Furthermore, it is also easier to source dry nitrogen for a system recharge than other gas mixtures used in similar clean agent systems.

6. Keep clean-up in mind

A fire event isn’t actually over until your vehicles get back up and running. Clean agents offer a significant advantage over traditional agents when it comes to post-suppression clean-up, especially for electrical compartments densely packed with sensitive controls. Traditional agents that are not electrically conductive, like dry chemical, can effectively extinguish fires, but they can leave residue that requires extensive cleanup and can affect the electrical components. In comparison, a clean suppression agent leaves no residue, helping to minimise clean-up and maintain the integrity and operation of intricate electrical systems.

Similarly, in engine compartments, single-agent liquid systems typically require less cleanup than single-agent dry-chem or dual-agent systems. Less cleanup can save time and help operations resume more quickly after activation.

Best practices for the best protection

Onboard fire suppression systems are ideal for heavy mobile mining equipment because they provide continual, 24/7 protection as vehicles move across mining sites. By following these best practices, installers and users can select the most effective onboard fire suppression system for each fire risk. Correctly specified fire suppression solutions help prevent equipment damage, protect personnel and prioritise sustainability while keeping operations moving into a safe, profitable future.

*Kristin Ryczek is Global Vehicle Product Manager for Johnson Controls

Caterpillar Safety Services looks to build safety resiliency with newest updates

Mining events, Mining safety, Mining services, , , , , ,

With safety no longer being a box-ticking exercise but a true measure of employee engagement, Caterpillar Safety Services says it helps build a strong culture where safety practices are embedded across an organisation. To aid this, the company has launched two updates to its programs contributing to resilient safety cultures.

The updated Safety Perception Survey and a program focused on human and organisational performance that have recently been announced leverage Caterpillar Safety Services’ 50 years of operation, along with the latest research and approaches to address safety excellence within organisations.

Today, Caterpillar Safety Services says it assists companies with improving the four components of a resilient safety culture, where safety is approached proactively, and all team members take ownership of safety. This expands to programs featuring equipment from all OEMs – not just Caterpillar. The components include:

  1. System – clearly defined safety expectations embedded in policies and procedures to identify and mitigate risk;
  2. Mindset – a shared mindset that safety is everyone’s responsibility, people make mistakes and an environment of openness that makes people feel safe to speak up;
  3. Leadership – specific, consistent leadership behaviours at all levels of the organisation that positively influence people toward safe work; and
  4. Ownership – occurs when all levels fully engage in the creation and continuous improvement of the safety system.

Trinnie Cortez, Industry Consultant, Caterpillar Safety Services, said the latest updates reflected ongoing trends in the industry that are relevant to safety people and operators on the front line in mining.

“We, at Caterpillar Safety Services, are close to our customers and, with these updates, are recognising not only feedback from the field but also from our technicians working with equipment on a daily basis,” he told IM on the sidelines of the SME MineXchange Conference and Expo, in Phoenix, Arizona. “The updated Safety Perception Survey, for instance, is a product of continuously communicating with safety steering teams and the facilitation of working groups. We continue to evolve our offering in line with what the market tells us.”

The Caterpillar Safety Services Safety Perception Survey analyses an organisation’s safety culture. Building on 35 years of research and study, the new survey updates language and modern concepts of safety culture excellence, adding questions related to psychological safety and human and organisational performance.

The new survey’s reports are streamlined with more modern visualisation of the data. They measure five safety activities – hazard identification, event learning, inspections, near miss and safety meetings – and address 11 cultural indicators, including caring climate, employee involvement, feedback, management credibility, training effectiveness and risk reduction. Importantly, they also show how safety is perceived differently among employees, supervisors and managers.

Human and organisational performance is a framework concept for talking about safety and creating a resilient safety culture, Caterpillar Safety Services explains. It is a mindset that allows organisations to build more error-tolerant systems by teaching leaders that expecting perfection from workers, processes, or procedures is not realistic.

Caterpillar Safety Services says traditional methods of managing safety systems centre around designing policies, standard work and processes assuming work happens in a straight line. Management sets the expectations, tells workers what to do and the workers do it the same way, every day.

“This method, however, does not account for organisational factors that can disrupt the system, such as employees not having the right tools for the job and adapting or making tradeoffs because they are still required to meet production targets,” it said. “Nor does it account for the individual factors that impact a worker’s awareness, or lapses in attention due to events in his or her personal life, such as a family emergency.”

When workers deviate from the safety plan or make mistakes under the traditional model, they may be scrutinised or punished to attempt to improve safety, but this can have the opposite effect and lead to a weaker safety culture.

Using human and organisational performance principles, Caterpillar Safety Services applies a new understanding of human behaviour to safety, it says. Leaders create an environment where employees feel empowered to speak up to share their ideas, struggles and mistakes. The organisation learns to improve its safety system continuously.

“With this framework concept, we are recognising what real leadership is within a safety context,” Cortez said. “Building and promoting such leadership is key to getting the whole workforce engaged with programs for continuous safety improvements.”

This results in a more engaged and proactive safety culture with improvements in morale, retention, efficiency and profitability, according to Caterpillar Safety Services.

Caterpillar Safety Services assists organisations with implementation of human and organisational performance principles through its Leadership Development and Coaching program.

“Tailored to the specific needs and objectives of the individual leaders, the program includes a mix of workshops, assessments and individual face-to-face sessions,” Caterpillar Safety Services said. “It helps each leader understand their strengths and areas for development in safety management, demonstrates how a leader impacts the safety culture, and creates personalised development plans for all leaders that align with organisational goals and processes.”

SafeGauge to continue ELW journey with launch of MultiTool Pro at IMARC

Mining events, Mining safety, Mining services, , , , , , ,

SafeGauge, which has a goal to eliminate live work (ELW) in heavy industries, such as mining, defence, construction, agriculture and oil & gas through the use of wireless/Bluetooth testing solutions, is set to unveil a new product at next week’s IMARC event, in Sydney, Australia, that, it says, promises to elevate vehicle maintenance to unprecedented levels of efficiency and effectiveness.

The MultiTool Pro allows technicians to connect to 12 SafeTest gauges simultaneously, from up to 100 m away. SafeGauge has a range of SafeTest Pressure Transducers (PT Series), Dial Indicators (DI Series) and Tachometers (TM Series), which, it says, are the go-to solutions for heavy industry applications.

The intuitive ‘plug-and-play’ touchscreen on the MultiTool Pro interface comes packed with a host of new features, including data-logging and graphing, with the ability to generate comprehensive reports that can be exported and shared via in-built cloud connectivity, according to the company.

Fit for heavy-duty applications, it comes with a rugged IP68 designed casing, with attached stylus pen.

Luke Dawson, Managing Director at SafeGauge, said: “We are thrilled to be a part of IMARC 2023 and share our latest innovations with industry professionals. SafeGauge is dedicated to transforming the landscape of heavy vehicle maintenance, and our wireless testing solutions are a testament to our commitment to safety, efficiency and innovation.”

By eliminating the need for technicians to work in close proximity to operational heavy vehicles (inside the machine footprint) through the use of such tools, SafeGauge says it ensures both the safety of technicians and the efficiency of maintenance procedures.

Martin Engineering addresses conveyor safety misconceptions

Bulk handling, Mining equipment, Mining safety, Mining services, , , ,

Martin Engineering is disputing the idea that putting conveyor equipment out of reach or inconveniently placed away from workers – known as “guarding by location” – is a valid form of safety.

After decades of safe equipment design and comprehensive conveyor safety training in the bulk handling industry, Martin Engineering experts have witnessed where “guarding by location” has led to a lapse in workplace safety, resulting in injuries and – in some cases – fatalities, the company says.

Most people readily accept that conveyors and other machinery require safety guards when positioned near workers or walkways. Guarding by location is the assumption that when hazards, such as moving conveyor belts, are positioned beyond the normal reach of a worker they don’t require a guard. Yet they can still present a serious hazard.

Worker risks from guarding by location

Some regulations define a general safe height for components based on the average height of workers. This means taller employees (1.82 m in height or more) can easily suffer an injury reaching up into a moving component that is 2.13 m above the ground. Working above machinery that is considered guarded by location exposes workers to increased severity of injury if they slip or fall to a lower level.

Most regulations do not account for the potential buildup of spillage underneath the conveyor or in walkways, which can easily change the distance between the working surface and a hazard. It’s also fairly common practice to purposely collect a pile of material or fill a bin to gain access for service or inspection of an elevated component. Using tools and methods that extend a worker’s reach while the belt is running is a hazardous activity that can contribute to serious – and possibly fatal – accidents.

Height prevents a worker from reaching hazardous areas until the reality of bulk operations proves otherwise

Hazards from above

By not requiring a physical barrier, guarding by location creates what is considered by some to be an exception to the general requirements for the guarding of hazards in the workplace. Several hazardous locations are beyond the normal reach of staff when working or walking under or around elevated conveyors. These hazards are commonly found in or around nip points between the belt and return rollers or drive components such as pulley shafts, couplings, drive belts, gears and chains. Additional hazards from falling components may be inadvertently ignored if considered guarded by location.

Guarding best practices

The logical solution to guarding by location is to simply install guards and baskets to protect workers from lateral and overhead hazards, while still offering safe and easy access. For maximum risk reduction, all nip points, shear points and moving or rotating components should be guarded, regardless of location or access. However, there is also no global standard for guard mesh sizes and mounting distance from the hazard. Most standards use a gauge to measure the distance which varies by mesh size. When a bulk material handling guard is placed relatively close to a hazard it greatly reduces the ability to inspect components without removing the guard, thereby encouraging guard removal for routine inspections.

It would be far better (and safer) to standardise on a few mesh sizes and mounting distances allowing maintenance workers to build guards to a short list of materials, using standard mounting distances and eliminating the use of the gauges. Below is the recommendation included in Martin Engineering’s book ‘FOUNDATIONS for Conveyor Safety’.

Put an end to the myth

Despite its nearly global acceptance as a concept in industrial safety, the practice of guarding by location remains a particular problem for overhead conveyor applications. It’s time to accept that as far as conveyors are concerned, ‘guarding by location’ is a myth. As such, it’s a concept that should be abandoned in order to make conveyors – and those who work on and around the equipment – safer.

Elphinstone set to put newly-acquired Beltor ‘Puller’ safety & productivity device into action

Equipment maintenance, Mining equipment, Mining safety, Mining services, , , ,

Elphinstone recently acquired the proven Beltor ‘Puller’ – an underground mine extraction device designed to safely recover buried equipment – as part of its ongoing commitment to safety and mine productivity.

Operator safety and mine productivity have always been a priority at Elphinstone, which has a long and successful history designing and manufacturing underground hard rock mining equipment from its headquarters in Burnie, Tasmania.

This was demonstrated in March of this year when it announced the acquisition of MED Pty Ltd, the owner of the IP for the underground Mine Extraction Device (MED) also known as the “Beltor Puller”, developed by the founder of Beltor Engineering, Aldo Beletich, back in the 1980s.

The MED was invented in response to a need by underground miners to extract buried or bogged equipment in a safe and efficient means without damaging the mine or negatively impacting production.

When Beletich invented the first Beltor Mine Extraction Device back in the 1980s, mining equipment was much lighter than it is today.

The first MED, with a pulling capacity of 90 t, was introduced to the market in 1988 to meet the needs of the underground thermal coal miners in and around Newcastle. With the increase in the size and weight of underground mining equipment, there was a need for larger extraction devices to recover buried or bogged equipment.

As a result, higher capacity MEDs were introduced to ensure that underground mining operations could return to full production with minimum delay. Subsequently, the 150-t (MED150) and 210-t (MED210) versions of the device were introduced in line with the industry’s growth.

In addition to the retrieval of buried equipment, the higher capacity models are also capable of extracting drill rods embedded in the rock face.

The expansion did not stop there. In 2020, the largest version of the extraction device was launched, the MED360, with a pulling capacity of 360 t for much larger underground coal and hard-rock machinery.

The MED range has revolutionised the way buried underground equipment is extracted and made this process safer, according to Elphinstone.

“What makes the (Elphinstone) MED unique is that it eliminates the need, damage and disruption of using other production equipment to remove the buried machine and operates in a more controlled and safe way,” Tim Mitchell, Elphinstone’s Global Sales and Marketing Manager, says.

“When the MED is towed into position in the mine, the boom is raised against the roof and the wheels are lowered on the floor, effectively wedging the machine into position. A bridle assembly is interlocked into the teeth of the MED racks which are then pulled via hydraulic cylinders.

“The process is conducted in relative silence allowing the operators to hear and see exactly what is happening during the extraction, a stark contrast to the traditional method with wheeled or tracked tow vehicles that produce noise and dust.”

The MED will be sold and serviced by Elphinstone direct to end users from the company’s manufacturing facility in Burnie.

Murray & Roberts Cementation highlights training evolution in mining sector

Careers in mining, Mining services, , ,

Training within the mining sector is a fast-changing field, driven by technological advancements, evolving safety standards and the need for a more skilled workforce.

Keeping up with these demands has been the focus of the Murray & Roberts Cementation Training Academy near Carletonville, South Africa, combined with ongoing attention on raising safety levels in pursuit of Zero Harm.

According to Tony Pretorius, Education, Training and Development (ETD) Executive at Murray & Roberts Cementation, this has meant constantly pioneering effective strategies that build excellence and discipline in the workplace.

“An important foundation for us has been the integration of technology in our training programs, incorporating tools such as virtual and augmented reality, e-learning, and online resources,” Pretorius says. “These technologies enhance the learning experience, improve knowledge retention, and facilitate the development of digital skills essential for working with advanced mining equipment and systems.”

At the same time, he highlights the promotion of a safety culture in mining. To achieve this, the academy places a strong emphasis on cultivating a safety-first mindset among trainees. By prioritising safety in all aspects of training, the academy helps instil a culture of vigilance, risk assessment and continuous learning – aligning with best practices for workplace safety in the mining industry.

“We also ensure that our training programs align with relevant mining regulations,” Pretorius says. “This equips workers with the knowledge and skills to adhere to the latest safety guidelines while keeping their workplace compliant with regulatory requirements.”

As an example of how digital technology has been leveraged in the learning space, he points to the academy’s use of virtual and augmented reality in the training process. These immersive technologies allow trainees to experience realistic, risk-free simulations of mining environments and scenarios.

“This approach not only improves knowledge retention but also enables the identification and correction of potential mistakes before they occur in real-world situations,” he explains.

Another important aspect of the modern training approach has been towards competency-based training. Here, the focus has shifted away from the mere completion of training programs, to the more detailed assessment of competence of workers in their specific roles. The focus, therefore, is on the development of practical skills, knowledge and attitudes that lead to improved job performance and overall safety. Pretorius also points to the vital role of what were previously referred to as ‘soft skills’ – competencies which are today proving to be as important as technical skills.

“In addition to technical skills, the mining industry recognises the importance of developing skills such as communication, leadership, teamwork and problem solving,” he says. “These skills are vital for maintaining a safe working environment, especially in high risk situations where effective collaboration and decision-making can prevent accidents and save lives.”

Beyond the daily work tasks, workers are also having to become more aware of sustainability and environmental issues. This is inevitable, as the mining industry faces increased scrutiny regarding its environmental impact.

“Training programs now include modules on sustainable mining practices, resource conservation and waste management,” he says. “This helps ensure that workers are aware of their responsibilities and the role they play in minimising the industry’s environmental footprint.”

Wabtec’s latest generation collision avoidance solution gains traction with new orders

IoT, Mining equipment, Mining safety, Mining services, , , , , , , ,

Wabtec’s Digital Mine division says it has received a series of orders for 3,500 of its new Generation 3 Collision Avoidance System (Gen 3 CAS) from three major global mining companies.

The capabilities of the new system will drive performance and safety improvements at the customers’ mining operations, the company says.

When Wabtec launched this system in June, it said its innovation focus was on shifting from traditional proximity detection to true collision avoidance.

Nalin Jain, President, Digital Intelligence for Wabtec, explained: “These orders demonstrate the Gen 3 CAS’s value and rapid market adoption since we launched the system in June. The Gen 3 CAS is the only solution aligned with the industry’s best practices that also meet the functionality requirements of our customers.”

Installing Gen 3 CAS across a customer’s mining operations will improve safety, bolstering their zero-harm objectives, according to the company. By minimising the risk of vehicle interactions, the Gen 3 CAS will contribute to reduced downtime, increased productivity and optimised resource utilisation.

Wabtec says its customers can confidently rely on this innovative solution to drive performance and achieve their operational objectives.

Wabtec Digital Mine’s Gen 3 CAS offers a range of class-leading advanced capabilities not seen on any other solution, according to the company. These include predictive beam curving, context-based definitive voice-based alerts, real-time self-test, superior accuracy via Ultra High Precision Global Navigation Satellite Systems and the most advanced rules and intelligence engine in the industry. The system’s brand-new user interface, validated by Professor Robin Burgess-Limerick, a human factors expert, has been designed so that vehicle operators receive appropriate feedback from the Gen 3 CAS, Wabtec says. It replaces “beeps-and-buzzer” technology with sophisticated, discreet, directional and audible warnings, enabling operators to work without distraction and respond instantaneously to audible alerts.

Jain added: “We are improving safety and operational efficiency, so we have entered into agreements with several global mining companies who recognise the potential of Wabtec Digital Mine’s Gen 3 CAS to transform their mining operations. These customers are installing the Gen 3 CAS to enhance their mining fleet’s safety standards and performance.”

Henro van Wyk, Vice President and General Manager of Wabtec Digital Mine, said: “We are thrilled that multiple global mining companies have selected Gen 3 CAS for their operations. These deals represent a significant achievement for Wabtec’s Digital Mine team positioning the business as the global leader in mining technology by redefining the meaning of true collision avoidance. Mining operations using the Gen 3 CAS will achieve new levels of safety, efficiency and productivity across their mining operations.”

ICMM report highlights fall in mining fatalities in 2022

Mining safety, Mining services, Sustainable mining, , ,

ICMM has, today, released a report that benchmarks the 2022 safety performance of its members, highlighting that 33 people from ICMM company members lost their lives at work in 2022.

This number compares to 45 in 2021 (after an additional two were retrospectively added to the count) and 44 in 2020.

ICMM says its members are unwavering in their commitment to operate responsibly, as they work to eliminate fatalities towards a goal of zero harm.

To support this commitment, ICMM compiles, analyses and publishes the safety data provided annually by company members, which collectively represent a third of the global mining and metals industry. The full report, ‘Safety Performance: Benchmarking Progress of ICMM Company Members In 2022,’ is available here.

The report analyses fatalities from ICMM company members based on the cause (or ‘hazard’) and provides safety performance metrics by county and company. In 2022, nine of the 33 fatalities were related to mobile equipment and transportation, and five fatalities were caused by falling objects. Company member operations in South Africa had the highest number of fatalities (seven), accounting for 21% of the total fatalities across ICMM members. Thirteen out of 26 members reported zero fatalities.

Rohitesh Dhawan, President and CEO, ICMM said: “Everyone deserves to work free from harm, within a safe and healthy industry environment.

“ICMM has remained steadfast in our belief that we can always find new ways to improve, and as we enter a period of unprecedented demand for minerals and metals, we will continue to focus on identifying new ways to eliminate fatalities from mining and metals operations.”

ICMM began collating and publishing data on members’ safety performance in 2012 with the intention of driving knowledge-sharing, transparency and continual improvement across the industry. This data is compiled using ICMM’s ‘Guidance on Health and Safety Performance Indicators’ which was updated in 2021.

Hexagon’s Mining division expands with dedicated underground mining portfolio

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Hexagon’s Mining division has, today, introduced HxGN Underground Mining, an integrated sensor-software portfolio built for the unique challenges of underground environments, at its HxGN LIVE Global 2023 event in Las Vegas.

Featuring what it says are robust systems for collision avoidance, drill optimisation and production planning, the new portfolio helps mines to achieve the best results while protecting drivers, pedestrians and equipment in the most demanding environments.

For Hexagon’s Mining division, meanwhile, it enables the company to further diversify its revenue stream, which is currently skewed towards the open-pit mining sector.

Hexagon says today’s announcement responds to industry demand as more mines push deeper beneath the surface for deposits and face ever more complex conditions. The aim is to provide mines transitioning from open-pit to underground operations – or those mining orebodies from surface and underground simultaneously – with a holistic solution for the life of mine.

HxGN Underground Mining, the company says, effectively creates a seamless technology transition from open pit to underground mining. Its safety suite, for example, leverages collision avoidance and operator alertness systems proven in more than 40,000 vehicles worldwide in open-pit environments.

Similar integration is at work in the portfolio’s operations suite, which helps mine operators and supervisors to manage underground fleet equipment and to optimise production in real time via a dynamic activity scheduler and fleet management system (HxGN MineOperate UG Pro fleet management system). Engineers, via the HxGN MinePlan Underground Engineering product, can avoid flawed mining processes and minimise downtime by using 3D visualisation, and CAD tools to create mine designs and activity-based schedules, the company says.

The portfolio’s optimisation software for production and development enables mines to achieve consistent blasting outcomes with high-precision drilling and optimal set-up processes. The company added to this portfolio recently with the incorporation of Minnovare. The Australia-based company has established four solutions – The Azimuth Aligner, Development Optimiser™, Production Optimiser™ and Minnovare Core – to improve the speed, cost and accuracy of underground drilling.

Beyond benefitting business, better drilling practices are good for the planet, reducing CO2 emissions and supporting sustainability goals, Mateus Quintela, Hexagon’s Head of Product, Underground Mining, said.

“We know mines are looking for ways to mine smarter, safer and in more environmentally and socially conscious ways,” Quintela says.

“HxGN Underground Mining will help our customers answer this search by increasing the efficiency of machines and miners throughout the operation. Well-choreographed scheduling will minimise the downtime of working areas, like headings and stopes, and there’s a real opportunity to reduce diesel emissions through better truck-to-loader planning.

“Perhaps most importantly, our new portfolio offers ways to ensure operators and supervisors are capturing and using safety data, so whether above ground or below it, everyone gets home safely.”