1. Please read this before using presentation
This presentation is based on content presented at the industry information session on risk-based hygiene management planning held in May 2015
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
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2. Our commitment
To work with industry to reduce serious accidents and incidents, and provide tangible support in achieving a positive cultural change.

3. Resources Safety’s focus

4. Diesel emission management plans

5. Management of diesel particulates in underground mines - status
The attached graph demonstrates the difference that can be made to the level of DPs being recorded at mine sites. The plot clearly shows a significant decrease in the level of readings collected between 2009 and 2011, and those samples collected between 2011 and In 2014, not a single sample result exceeded the OEL of 0.1 mgs per cubic metre.

6. Current situation
Mines should have a diesel emission management plan based on the 10-point checklist in guideline
Plan should be:
being implemented
include measures that demonstrably reduce diesel emissions
The expectations of the Department are that by now all mine sites should have developed and implemented a Diesel Emission Management Plan. This Plan should be based upon the 10 point checklist, contained within the Department’s Diesel Emission Management Guideline, and should include measures designed to actually reduce the level of DPs produced by their operations.

7. 10-point checklist Examples of 10-point checklist from:
companies at individual mine sites
new technology available from service providers
Aim: Reduce diesel emissions
The 10 point checklist is the basis for creating a Management Plan. Many of the current innovations emerging from industry address specific points from this checklist. The purpose of this presentation is to make you aware of what is being done at various mine sites, and what is available from service providers.

8. Point 1. Appoint a champion
To be successful:
each site or company must have a driving force or person
sites need to commit to improvements
development and implementation of plan needs the support of all parties on site (or it will fail)
responsibility rests primarily with Ventilation Officers, working in conjunction with site’s OHS department
The department’s experience, when visiting mine sites, is that only those with a properly developed Management Plan, which can clearly be demonstrated as being implemented on site, are making any inroads into reducing diesel emissions. Many Management Plans sighted, are little more than motherhood statements, and at those sites where there is no clear commitment to make it happen, the Management Plan is collecting dust on management’s book shelf. As the person responsible for the purity and clarity of ventilation air, the Ventilation Officer should be the prime driver of the Emission Management Plan. However, if they do not have the support of Management, the OHS Department, and the Maintenance Department, the Plan will wither and die.

9. Point 2. Buy clean
Major advances in equipment will lower or reduce the level of exhaust emissions
Tier 4 engines beginning to be fitted to new equipment on the market
Companies trialling these include St Barbara (Gwalia Deeps mine)
Use replacement of old equipment as an opportunity to “Buy Clean”
There have been major advances in the standard of diesel engines available on the market. Tier 4 clean burning engines are becoming more prevalent in industry. Any new operation, just starting up, or established operations, due to change out equipment, should take the opportunity to source new technology engines, rather than older Tier 1 and Tier 2 types. Also, some companies offer Emission Reduction Packages, consisting of new injectors that can be retrofitted to older engines.

10. Point 3. Scrutinise fuel and oil supplies
Source and storage of fuels and lubricating oils is a significant component of management plan
Sites using 10 ppm or better sulphur content diesel fuels - may not appreciate the importance of low ash oils
Retro-fitted reduced emission packages will only produce reduced emissions if used in conjunction with low ash oil
Storage of fuels is important
introduced dust, water, algae, etc. lower the cetane value
large quantities of on-site fuel going “stale” upon standing
Often the purchase and storage of fuels and lubricating oils are not give the level of attention that they warrant. The performance of the diesel engine, and the level of exhaust emissions, are only as good as the fuel and oils used. Diesel fuel should contain 10 ppm or less of sulphur, and care should be taken regarding its transportation and storage. The large quantities of fuel regularly carried on site (to avoid shortages during natural disasters such as flooding, which may cut supply lines), are open to contamination by dust, rain, or algae, all of which will lower the cetane value of the fuel, and the performance of the engine.
Unlike fuel, which is universally sold as low sulphur, the same attention to the purchase of low ash oils, is not frequently demonstrated. The contaminants contained within oils, become the nucleation points for the formation of DPs, in the ash which is the products of combustion.

11. Fuel additives currently available
Some sites are trialling fuel additives:
intended to improve the burning characteristics of diesel fuels, reducing emissions and make DP filters more effective
examples include a fuel-borne catalyst, in use with fleet at St Barbara’s Gwalia mine
some sites are already considering the use of a urea-based product, intended to absorb the increased levels of Nox (associated with some reduction methods)
Fuel additives have been around for some time, but recently their use has evolved beyond improving the burn of the carbon making up the soot trapped in DP filters, and begun to address the elevated levels of NOx generated when carbon levels go down at the expense of rising nitrous oxide. Urea-based products are starting to make an appearance on mine sites. This product has been used on Perth buses for some considerable time.
Examples include a fuel borne catalyst, in use with the fleet at St. Barbara’s Gwalia Mine. Containing iron, most of these products lower the ignition temperature of soot collected in DP filters, ensuring better conversion to ash

12. Point 4. Conduct baseline monitoring
Carry out an evaluation of site’s diesel fleet’s engine performance:
helps to know the baseline operating characteristics
if new, any deterioration in performance can quickly become evident
if old, the decision to retire or retrofit with filters is aided by this baseline information
variations between the performance characteristics of identical items of equipment (e.g. 2900s) can indicate a drop off in performance of one asset
Initial Baseline Monitoring of the entire site diesel fleet serves multiple purposes. It identifies poorly performing engines, which may benefit from being retired, or retro fitted with an exhaust treatment device. It establishes the initial starting value for each item of equipment in the fleet. This value may be quite low, for new equipment, and high for older items in the fleet. Regardless, any deterioration in the initial readings, will indicate a drop off in performance of that engine. Remedial action can then be taken. Baseline testing also highlights any differences between similar items of equipment. For example, if among three 2900 loaders, two produce 44 mgs of carbon and the third generates 88 mgs, there is clearly a problem.

13. Real time monitoring of the diesel fleet
Technology allows diagnosis of the undiluted exhaust emissions of diesel engines
Used in conjunction with a gas analyser, can do a complete diagnosis of a vehicle
Results can be related to traditional NIOSH 5040 methods
The development of new real time measuring equipment, for monitoring DPs has taken a quantum leap in recent years. Real time analysers now exist for undiluted exhaust testing, ambient atmospheric monitoring, and personal exposure sampling. The best of these instruments align themselves with the traditional NIOSH 5040 techniques, which rely upon a filter to collect a solid sample of dust or soot.

14. Point 5. Retro-fit diesel particulate filters
This measure is still the most potent in any management plan:
sites that have utilised filters have seen greatest reduction in exhaust emissions
quality of filters has improved considerably, with less maintenance issues
equipment is monitored before and after fitting of filter
despite the success of new technology, such as the Tier 4 engines and one OEM’s emission reduction package, manufacturers are still fitting DP filters to the tail end of their exhaust emission systems
In conducting site visits and analysing Contam data submitted by mine sites, the most noticeable feature has been that those sites fitting DP filters to their diesel fleet, have reaped the benefits of doing so. While many of the other measures, included in the 10 point checklist, may lower or reduce emissions by values such as 10 or 20 percent, DP filters will usually reduce DP readings by 80 to 90 percent. They clearly provide the best bang for your bucks.

15. Point 6. Role of maintenance
Ongoing maintenance is a significant factor in management plan:
includes maintaining engine performance and testing of retro- fitted DP filters to ensure they are functioning, and check integrity of enclosed cabins
diesel engine will be properly maintained if specific maintenance checklist followed
poor maintenance has resulted in build up of back pressure in DP filters → blown up engines
cannot overstate importance of good maintenance in the management plan!
Maintenance is a key component in the Management Plan. Only with the aid of the Maintenance Department, will the implementation of the Plan be successful. Maintenance impacts on other areas of the Plan, such as DP filters, and the effectiveness of enclosed cabins in protecting the operators from exposure.
Maintenance is such a significant component in the 10 point checklist, that it has its own Maintenance Checklist, also included in the Department’s Guideline. If this checklist is adhered to the diesel engine will be properly maintained
Poor maintenance can result in breakdowns in filter performance not being detected. Poorly maintained door seals, cracked or broken windows, and blocked filters in cabin air conditioners, can result in workers being exposed to fumes.

16. Point 7. Establish the ventilation requirements
Ventilation available in the mine must be adequate to support diesel fleet in use
If ventilation is inadequate, or cannot be improved, the size of the diesel fleet must be reduced
Well-maintained ventilation system is essential to ensure exhaust emissions are as low as possible
Actual air flow required to keep the DP levels below 0.1 mgs/cubic metre is much greater than that required to satisfy the dilution of carbon monoxide and oxides of nitrogen
The importance of Ventilation, and the role of the Ventilation Officer, cannot be stressed too strongly. One factor that is often misunderstood, is that ventilation considered sufficient to dilute and disperse gases (such as carbon monoxide and oxides of nitrogen), is not adequate to keep the level of DPs below the accepted OEL of 0.1 mgs per cubic metre. Consequently, ventilation standards need to be a lot higher than currently observed in most mines. Responsibility for this lies squarely with the Ventilation Officer, but he cannot do it alone. All parties must assist, from service crews staying on top of torn and damaged vent ducting, to management being prepared to commit to larger ventilation fans and expensive monitoring and control devices.

17. Real-time monitoring of the mine environment
New system to monitor the entire mine environment:
comprises a range of sensors for gases, DPs, temperatures and humidity that report back to the mine control room or Ventilation Officer’s computer
used in conjunction with V.O.D. devices, such as remotely operated blast doors (or regulators), ventilation can be controlled by turning fans on and off at will, and opening and closing regulators to disperse and dilute fumes
The technology exists to monitor all the key indicators of the mine environment, and make the necessary changes, via remotely operated control equipment. The installation of a fibre optic cable allows the use of a multitude of sensors, capable of reading temperatures, humidity, gas levels, and DP levels, and then to effect the required changes by operating fans and regulators, from the Ventilation Officer’s desk computer.

18. Point 8. Monitoring of the environment
To measure reductions in the levels of exhaust emissions, ongoing real-time monitoring is required.
Emissions emanating from the diesel fleet - carry out undiluted tailpipe emission monitoring
Level of DPs present in ambient atmosphere of work environment - use real-time air monitoring units
Degree of exposure of workers to DPs present in their work environment (e.g. inside enclosed air conditioned cabins) - use either
real time monitors or
dust collecting cassettes containing filters that are later analysed
All personal DP sampling reported to CONTAM has used the NIOSH 5040 analytical method to quantify elemental carbon exposure, which requires the capture of particulate onto a quartz-fibre filter that is then analysed at a NATA accredited laboratory.
Diesel particulate, measured as Elemental Carbon (EC), is the surrogate component of diesel exhaust that can be reliably measured using the NIOSH 5040 analytical method.
Real-time technology replicates the NIOSH 5040 method, using laser absorbency / transmittance to determine sample concentrations, whilst using a size-selective sampler of 0.8µm to reduce interference by other mine dusts and aerosols.

19. Examples of real-time monitoring of the environment
DMP does not promote or endorse individual suppliers or products

20. Point 9. Develop and implement a training program
Enlisting all parties involved in diesel emission management plan is essential to its success
Develop training programs for all personnel, from line managers, maintenance mechanics, OHS technicians, to operators
Important that everyone understands their role and its importance to the success of the program
Training Modules should be developed for all aspects of the operation. Such modules should provide all parties concerned with an understanding of what role they play in the successful implementation of the Management Plan. This includes the fitters and mechanics in the Maintenance Department, who carry the responsibility for ensuring all engines are performing to specifications, DP filters are functioning correctly, and protective enclosed cabins are maintaining their integrity. Operators should be made aware how much of a difference driving their vehicles properly can make. Avoiding unnecessary idling, excessive revving of the engine, and stop start duty cycles.

21. Point 10. Evaluate exposure controls and PPE
While the management plan will reduce emissions, it is still necessary to deal with the reality of workers exposed to diesel particulates:
regularly review the effectiveness of enclosed cabins and PPE
consider the integrity of cabin seals, air conditioner filters, dust masks and respirators
some sites using HEPA filters on cabin air conditioners have halved the exposure values
The effectiveness of equipment, designed to protect workers from exposure to diesel emissions, should be checked against the data collected from the CONTAM sampling program. Any exceedances should be reviewed to determine if inadequate protective equipment or PPE is involved. The integrity of door seals, windows, and air conditioner filters, on enclosed cabins, should be regularly tested.

22. Example of what is possible
CAT 2900 Bogger photographed loading four 50t underground mine trucks while conducting DP sampling from return air drive
Clarity of air is testament to effective emissions management at the source
Mine 6 – Always difficult to obtain quality photographs UG however clarity of ambient atmosphere evident
Operation of such machinery would generally produce significant volumes of exhaust emissions that would be clearly visible and reduce the clarity of the images, particularly during change of direction by the equipment or while under full load.
This site had a comprehensive DP Management Plan and invested in preventative controls such as quality exhaust filters, low sulphur fuels, low ash engine oils, more frequent air filter replacement (150hrs), a regular planned maintenance regime, and effective ventilation.

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