Please read this before using presentation This presentation is based on content presented at the Mines Safety Roadshow held in October 2013 It is made available for non-commercial use (e.g. toolbox meetings, OHS discussions) subject to the condition that the PowerPoint file is not altered without permission from Resources Safety Supporting resources, such as brochures and posters, are available from Resources Safety For resources, information or clarification, please contact: or visit 1
Why is design so important to safety? 2
What is safety in design? Safety in design is aimed at preventing injuries and disease by considering hazards as early as possible in the planning and design process. 3
Design improvements over time 4
Concept evaluation Conceptual design Front-end engineering design (FEED) Detailed design Construction Field construct and install Production or operation How big is your window of opportunity? Concept selected Final investment decision (FID) Field activities Cost to change Source: NOPSEMA
6 Concept development Detailed design Shop fabrication / manufacture Site construction and installation Production operation Maintenance, refurbishment and repair Modification or expansion Demolition or relocation Safety in design life cycle Safety in design life cycle See code of practice on safe design
What responsibilities do you have? Mines Safety and Inspection Act 1994, section 14 (1) A person who designs, manufactures, imports or supplies any plant for use at a mine must, so far as is practicable – (a) ensure that the design and construction of the plant is such that persons who properly install, maintain or use the plant are not, in doing so, exposed to hazards 7
Reasonably practicable Sacrifice in time, money and trouble 8 Quantum of risk severity and likelihood of event
What are the consequences of poor design? Risk of injury or loss of life Environmental or equipment damage Loss of income Low productivity Higher operating costs Higher maintenance costs Reduced asset life Higher employment and workers’ compensation expenses 9
Elimination Substitution Isolation Engineering Administrative control PPE Remove the hazard or hazardous work practice Replace the hazard or hazardous work practice with a less hazardous one Isolate or separate the hazard or hazardous work practice from people Modify tools or equipment to minimise exposure to hazard Modify work practices (e.g. procedure, training) to minimise exposure to hazard Last resort when other controls not practicable 10 Hierarchy of control – start at the top Increasing effectiveness What works? 10
What is wrong with this? Access way next to conveyor take-up pulley 11
What is wrong with this? Lifting lug welded to outside of conical bottom on powder-handling bin 12
Standard drawings – lifting lug example 13
What is wrong with this? Bag filling station – flat belt conveyor with roller bed lead-off conveyor 14
What’s wrong with this? Tyre inflation cage 15 “Homemade” truck tyre cage modified with additional steel plating Source:
What is wrong with this? 16
Flaws in the design 17
Top rail 18
Bottom rail Top drive gear 19
Consider not the cost of fixing a problem in the design stage, but the cost of not fixing a problem in the design stage!