DEMİR EXPORT – FERNAS JV
EYNEZ EAST UG COAL MINE
Risk Management Program
Hacı KARAKUŞ
HSEC Manager – Demir Export A.Ş.
December 2014
Contents
Eynez East Coal Mine Introduction
Risk Assesment Methodology
Major Hazards
High Risk Areas
Risk Treatment Plan
Conclusion
Introduction
East Eynez Coal Mine
 Eynez East UG Coal Mine is located in the vicinity of Eynez village,
35 km South of Soma; 106 km North of Manisa City.
 Eynez East is on the TKI concession of Soma Basin.
 Demir Export – Fernas JV (DEF) to all required surface and
underground facilities to produce 2.5 million tonnes per year over
16 years of mine life.
 Coal seam is 22-29 thick, brown coal (lignite)
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Introduction
East Eynez Coal Project was tendered out by Turkish Coal Enterprises (TKI)
in 2011.
DEF started field work in May 2012.
Project Schedule:
2012-2015 : Mine Development Period
2015-2016 : Start-up and ramp up period (1.5 Mtpa)
2016-2030 : Full production (2.5 Mtpa)
Selected Mining Method:
Longwall Top Coal Caving for safety and production capacity
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Introduction
45 exploration drillholes were done by MTA for TKI. In addition DEF have done 8
more drillholes to develop 3D resource model for mine design and planning
purposes.
Open Pit
Mine (TKI)
New drillholes were drilled;
• To improve coal reserve
• To validate the formations
Drillholes
Locations
Pillar (to
protect Village)
Eynez
Village
• Collect geotechnical data
• Collect data for gas content
• Detailed mine plan
5
Infrastructure
Coal Blocks
Production Panels
Main Gallery
Ventilation Gallery
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Infrastructure
Fully mechanized longwall top coal caving mining
method (LTCC)
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Infrastructure
Coal and Personnel Transportation
• Coal will be transported to surface through belt conveyors. All belt conveyors convey to
international coal mining standards ,1200 mm wide and flame proof. Main haulage belt is steeel
supported while others are solid woven belts.
• People who work in the mine and equipments mainly transported to work areas through mono rail
system.
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Infrastructure
Linear Development
• 13 production panels will be mined out over life of mine, for all panels total
maingate and tailgate roadways will reach 45.000 meters through LoM.
• Advance of the ventilation drift is 1716 m, by mid of Nov. 2014
• Advance of the main haulage drift is 1580 m, by mid of Nov. 2014
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Mining Method
Longwall Top Coal Caving Method:
Each coal level is divided into
two sections (upper and lower
excavation section)
The lower section is 3,5 m
high and secured by the
hydraulic support system, coal
is produced by shearer.
The upper section 5 to 10 m in
height, is exposed to dynamic
stress conditions due to
crumbling of the coal layer.
To sum up, 70% of Coal
production will be provided by
free-falling and 30% by
shearing.
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Mining Method
WHY LTCC?
Mine Safety
• Lower face heights result in improved face control, smaller and less
expensive equipment and improved spontaneous combustion control in thick
seams, through removal of the majority of top coal from the goaf.
Resource Recovery and Mine Financial performance
• The LTCC method enables extracting up to 90% of seams in the thick coal
seams.
Operating Cost
• Since only 30% of coal is cut and the rest is free caving coal, operating cost
for LTCC is typically lower than classical longwall operation.
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Longwall Equipment
Production equipment
• Shearer
• Hydraulic Shield Support
• Front AFC (armoured face conveyor)
• Rear AFC
Hydraulic Shield Support
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Equipment
Haulage and Transport Equipment
• Conveyors
• Armored Chain Conveyor
• Belt Conveyor
• Monorail
• Diesel Monorail
• Shunting Trolley
Belt Conveyor
Chain Conveyor
Monorail
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Equipment
Face/drift Development Equipment
• Roadheader
• Tunnel heading and loading machine
Roadheader
Tunnel Heading and Loading Machine
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Risk Assessment
• The site team have carried out a Broad Brush Risk Review (BBRR)
for Eynez East Underground Coal Mine. The key objectives of the
BBRR are to :
1. Identify the groups of major hazards those require detailed risk
assesment by using bow tie analysis method.
2. Confirm the qualitative risk priority and
3. Provide a list of hazards that engineering and safety personel can review
to ensure there are currently policies, procedures and strategies in place
to control these hazards.
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Risk Assessment

The Bow Tie method is used extensively in hazardous industries

Forms the basis of the risk assessment

Focus is on:


What can go wrong and why?
Causes/Threats/Hazards

How do we prevent it?
Preventative Controls

If we do lose control, how do we limit the effects
Reactive Controls
A Bow Tie model is developed for all the identified “major hazards” which includes
specific hazards for the Eynez East Underground mine under Enyez Village
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Risk Assessment
Causes/
Threats
Hazard 1
Hazard 2
Preventative
Controls
Reactive
Controls
Loss of
Control
Outcomes
Near Miss
Minor Loss
Hazard 3
Hazard 4
Major Loss
Hazard 5
Catastrophic
The focus is on the hazards and controls
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Risk Assessment
Causes/
Threats
Gas
Preventative
Controls
Reactive
Controls
Near Miss
Gas Drainage
Gas monitors
Electrical
Equipment
Failure
Ex Rated
Equipment
Equipment
maintenance
Outcomes
Gas
About to
Ignite
Auto shut
down of
equipment
Minor Loss
Withdraw
personnel
Major Loss
Emergency
Response
Catastrophic
Everyone has responsibilities for the controls
not just Safety people
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Risk Assessment
 By its definition, major hazards have the potential, if not controlled
effectively, to result in catastrophic outcomes therefore all are considered
high risk (high consequence even if the likelihood is very low) and
therefore all require detailed analysis to develop risk treatment plans to
reduce the risk to ALARP (As Low As Reasonably Practicably).
 Team workshops were then conducted on the high risk areas,
 Major Hazard = those hazards which have very high consequence (eg)
multiple fatalities or significant loss (immediate or over time)
 22 major hazard groups were identified.
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Introduction
The top 10 Major Hazard groups were identified for review process are:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Spontaneous Combustion
Strata Instability
Gas Explosion
Entanglement, Conveyors, Caught in and Struck By Equipment
Inrush / Inundation
Emergency Response
Electricity
Carbon Monoxide (CO) / Gas Asphyxiation / Atmospheric Contaminants
Underground fire
Airblast
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Risk Assessment
• The residual risk of spon com, gas explosion, and strata failure are still
high because the level of consequence is still extreme should an
unwanted event occur. Risk level can be reduced through the effective
implementation, monitoring and review of the risk treatment plan.
Managing the controls at all times is critical during operation.
• The Risk Treatment Plan (RTP) for spon com, strata and gas explosion
was the starting point only and it is reviewed and updated by technical
specialists with more information obtained and analyzed. The plan is
based on the input from the team members with the information and
understanding of the risks at the time. This may require review and change
in the future if required.
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Risk Assessment
• Strata instability / failure :
•
The team identified and defined 15 hazards that need careful consideration by
technical personnel and specific controls. Additional recommendations were made
to improve the adequacy of the current and planned controls. Critical controls
included development of ;
•
•
•
•
Strata Control Management Plan,
Cave Management Plan,
Subsidence Management Plan, and
An effective mine design,
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Risk Assessment
 Mining affects on Eynez Village

Subsidence and strata affects

Vibration

Water loss or impact on water quality
Pillar (to protect
Village)
Eynez
Village
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Risk Assessment
 Mining near to or underneath an operational open cut mine
 Water inrush if flooded
 Blasting
 Pillar and strata issues
Open Pit Mine
(TKI)
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Risk Assessment
 Mining next to old underground workings

Water inrush if flooded

Pillar and strata issues
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Risk Assessment
 Mining through faults
 Pathways for water and gas
 Pillar and strata issues
 Longwall operations difficult (eg) slow advance which leads to
deteriorating strata conditions in gate/tail roads
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Risk Assessment
 Mining in thick seam and use of LTCC
 Caving issues (eg) mudrush (fines and water in goaf / cave zone)
 Pillar and strata issues
 Longwall operations difficult
 Spon com
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Risk Assessment
 Gas – high gas concentrations
 Gas explosion
 Effects on strata instability (eg) coal outbursts
 Asphyxiation
 Lower coal seam interconnectivity and through faults
 Fire
 Carbon Monoxide
 Effects on ventilation flows
 Spontaneous Combustion
 The coal has a high propensity for spon com
 Goafs
 CO inflows to other areas
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Risk Assessment
Additional controls were developed throughout the hazard identification section of the risk
assessment with a focus on the hierarchy of controls as depicted in the figure below.
Hierarchy of Controls
1. Eliminate the Hazard
2. Substitute / Minimise
3. Engineering Control
 Redesign
 Enclose
 Isolate
4. System Controls
 Safe Work Procedures
 Training
 Warning Devices
5. PPE (last line of defence)
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Conclusions

At Eynez East Coal Mine three major hazard groups were identified.

DEF internal control procedures and applications are developed.

DEF Team suitably being trained.

DEF Management Commitment, DE vision covers these major risks

DE Safety Management Plan and applications covers the risks.

Outside Services and Studies for Spon Com, Strata and Gas explosion

Purchasing fit for purpose systems to reduce the impact of risks.

Continuous training, monitoring and auditing.

Reporting all incidents and accidents.

Proactive HS applications.
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THANK YOU
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