North Goonyella Mine Fire. Twenty Four (24) Relevant 2017 and 2018 Methane and Spontaneous Combustion HPI’s.

These are the High Potential Incidents between the 30th January 2017 and 1st September 2018

The first 3 were all Reported on the 31st January 2017 to Inspector Kevin Pointer at 10:32 am

These 2 Directives were issued in February 2017 and according to Inspector Marlborough were satisfied on 16th March 2017.

168 Directive to review safety and health management system and principal hazard management plans

To review the Principal Hazard Management Plan for Gas Management which shall include the review of risk assessments, Trigger Action Response Plans, and to implement effective adequate controls for the management of flammable gas. This includes demonstrating the training and competence of all persons with obligations for this hazard.

166 Directive to reduce risk

To review the application of adequate controls to ensure that any general body concentrations of flammable gas that exist in any workings do not eventuate in concentrations that present an unacceptable level of risk. This requires the implementation of controls that are in accordance with the hierarchy of controls with respect to the magnitude of this hazard.

The due date for both Directives was 16th March 2017 and both have now been satisfied.

There is not an HPI for a further Four (4) months.

The other 21 HPI’s occur between July 2017 and September 1st 2018.

I have included the

Level 4 meeting with the SSE Carter and UMM Romanski on the 20th November 2017
Level 3 held on the 6th February 2018 with those ERZ Controllers Shift Managers and Control Room Operators who were known to have direct involvement in mismanagement of methane levels during January 2017
Comments about March 14th 2018 MRE stating that a Structured Audit of the PHMP for Gas Monitoring would take place on a yet to be set date

30/01/2017

1) 4:54am and 05:25am

As a result of a higher CH4 levels in the 9North TG roadway between 4:54am and 05:25am production was stopped and all LW operators have withdrawn from the face to the last open cut through.

OTHER INFORMATION/DETAIL: Immediate action was stopping the production. None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.42%. Crews were informed about the incident.

2) 8:55pm and 12:00 pm LOCATION: 9 North LW Face

As a result of high CH4 levels in 9North TG roadway between 8:55pm and 12:00 pm production was stopped and all LW operators have withdrawn from the face to the last open cut through:

Immediate action was stopping the production. None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.42%. Crews were informed about the incident.

As a result of a higher CH4 levels in the 9North TG roadway between 1:20am and 03:10am production was stopped and all LW operators have withdrawn from the face to the last open cut through.

3) 31/01/2017

01:20 to 03:10 LOCATION: 9 North LW Face

As a result of a higher CH4 levels in the 9North TG roadway between 1:20am and 03:10am production was stopped and all LW operators have withdrawn from the face to the last open cut through.
Immediate action was stopping the production. None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.42%. Crews were informed about the incident.

DATE:

11/07/2017

TIME:

11:40 to 14:31

LOCATION:

9 North LW TG Roadway

To maintain 9 North LW TG CH4 Levels, it was necessary to perform the maintenance tasks on the Gas Engine and the surface gas lines. Both the Gas Engine and the Blo Skids had to be stopped to allow the maintenance tasks to be completed.

As a result of these activities CH4 levels in the 9North TG roadway remained above 2.5% with the pick value of 3.18% between 13:00 pm and 16:00pm. There was no production underground due to the maintenance shift and all of the LW operators were relocated from the face to perform the other activities outbye until all surface work was completed and the TG CH4 Levels returned to below 2.5%.

OTHER INFORMATION/DETAIL: Prior to any work on the surface LW crew was informed about all the activities. None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.185%.

Marlborough 12/07/2017 09:00

DATE:

12/07/2017

TIME:

11:40 to 14:31

LOCATION:

9 North LW TG Roadway

Due to the reported increased vibration on one of the bearings of the Main Ventilation Fan MF008, the fan had to be stopped for maintenance between 09:50am to 13:50pm. During the startup of the fan the pressure increase from 1400Pa to 1900Pa caused increased quantity of CH4 to be drawn from the goaf elevating levels above 2.5% between 14:00pm to 14:52pm with the brief peak value reaching 3.9%. Prior to the fan startup all personnel has been withdrawn from the TG Roadway. Due to the maintenance shift there was no production underground.

OTHER INFORMATION/DETAIL: Prior to the fan stoppage the whole crew has been informed about planned activities. None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.193%.

Marlborough 17:07 (5 Hours)

DATE:

03/09/2017

TIME:

12:40-16:33

LOCATION:

9 North LW TG Roadway

Due to the sudden Barometric Pressure Drop and a blockage of the drainage hole the CH4 levels in 9 North TG roadway remained above 2.5% with the peak value of 2.65% between 12:40 pm and 16:33pm. The production was stopped and there were no activities or personnel in the affected area.

OTHER INFORMATION/DETAIL: The CH4 level returned to below 2.5% when the barometric pressure rose up

Marlborough 06/09/2017 at 09:52 (3 days)

DATE:

05/11/2017

TIME:

00:52-02:00

LOCATION:

9 North LW TG Roadway

During the investigation of the power trip to the LW face it was noted that the several blowers appeared in the floor located behind the chocks #141 to #145 releasing CH4 and causing the general body of air in the TG roadway to rise from 1.6% and remain above 2.5% with the peak value of 2.95% between 00:52 am and 02:00am. No person was affected by the elevated levels of CH4.

OTHER INFORMATION/DETAIL: During the event the shearer was at #48 chock heading down to the MG. Crews were informed about the incident.

Neil Randolph 07:27 (>6 Hours)

LEVEL 4 COMPLIANCE MEETING 20th November 2017

NGC methane gas exceedances experienced at NGC around January 2017

Today, Monday 20 November, a Level 4 meeting was conducted between the Mines Inspectorate and North Goonyella Coal (NGC) mine management.

Present in the meeting were:

Mines Inspectorate;

Chief Inspector of Coal, Russell Albury
Deputy Chief Inspector of Coal; Shaun Dobson Regional Inspector, Les Marlborough
Inspector, Richard Gouldstone NGC Management:
Site Senior Executive (SSE), Mike Carter e Underground Mine Manager (UMM), Marek Romanski
Operators representative for Peabody(Vice President), Peter Baker.

The meeting objective was stated as a closure of the NGC methane gas exceedances experienced at NGC around January 2017. The NGC team objected to the level 4 on the basis of discussions held in March and the outcome of that meeting consequently demonstrating that the situation is now under control.

It has taken the mine inspectorate, since January, until now to be in a position to conclude it’s investigations and conduct the compliance review process.

As a result of the compliance review it was recommended that the SSE, UMM and the Ventilation Officer (VO) at the time, David Craft, to attend a level 4 compliance meeting with the chief inspector.

It is noted and recorded that NGC dispute some of the facts described in the Inspectorate findings. These seemed to be centred around the reporting of methane trips at the Main Gate(M/G) and the nature of those trips.

The Chief Inspector pointed out in the meeting that NGC were free to object and ,if it were determined that some of the facts were incorrect, get the facts corrected on the record.

However, these facts do not change the occurrences of general body methane concentrations in excess of 2.5% in the Longwall return recorded in the data provided by the SSE and analysed by the Inspectorate in the investigation.

Carter Romanski 2.5% CH4 L4 20 Nov 2017.pdf

DATE:

25-26/11/2017

TIME:

N/S

LOCATION:

9 North LW TG Roadway

During the Night Shift Production in 9North LW Panel, several goaf falls flushed out three times a CH4 gas into the roadway increasing its level for a very short time above 2.5 % . Each time production has ceased until the TG CH4 Levels returned to below 2.5%.

OTHER INFORMATION/DETAIL: None of the crew members were exposed to the dangerous levels of methane. Face average CH4 levels were at 0.268%.

Marlborough 12:06 (12 Hours)

6th February

Mines Inspector, Richard Gouldstone and Regional Manager, Inspector Les Marlborough, addressed a number of Shift Managers and ERZ Controllers employed at North Goonyella Coal Mine. The meeting was to discuss the details of the analysis of the atmospheric monitoring data for Longwall 9N return airway during the month of January 2017.

The meeting was conducted as a consequence of the investigation carried out by the Mines Inspectorate into the methane issues that occurred at the Mine during January 2017.

The meetings addressed those ERZ Controllers Shift Managers and Control Room Operators who were known to have direct involvement in mismanagement of methane levels during January 2017 and involved other mine officials who were also at the Mine during that period. It was decided that all needed to be made aware of the situation for future reference.

The significant points that were apparent and brought to the attention of the North Goonyella representatives were as follows:

Numerous occasions where the Tailgate general body methane concentrations exceeded 2.5%. This was followed by failures to conduct withdrawals to a place of safety and continuing with production operations whist methane was in excess of 2.5%.
Inconsistent alarm responses with the application of TARP’s 024 and 025.
Inadequate investigations into triggered alarms from tube bundle monitoring points.
The continuation of production for 7.5 hours when the real time monitoring point for the Tailgate was in bypass.
Risk assessment NC-MIN-RSK-LW029 which was a review of the TARP 024 to reduce the trigger levels. This was dated as being conducted on the 9th February which was 10 days after the letter from the Chief Inspector was issued in relation to the matter of 2.5% general body methane concentrations.

The lack of adequate hazard identification in this risk assessment was concerning given that the only ‘Unwanted Event/ Hazard Release” was the ” Escalation of methane levels in the Longwall return to >2.5% resulting in the loss of the TG as an escapeway” . The three reported HPl’s from the 30th and 31st of January were also reported as sub section 7 of Schedule IC “an unplanned event that causes only 1 escapeway from the mine to be available for use”. The hazard of methane explosibility had not been considered.

6. Inconsistent inspection and recording of environmental readings for the Tailgate. This also includes goaf stream sample results at the time of taking this sample.

7. No evidence on the statutory officials reports of re-inspecting the work area after the withdrawal of coal mine workers due to the TARP level being triggered

8. The undertaking of Ventilation Changes on night shifts when TARP triggered elevated methane events have occurred.

DATE:

26/02/2018

TIME:

15:48

LOCATION:

NGC-Underground Workings

During the severe thunderstorm, a power surge from the lighting strikes caused the Main Fans to Trip. The main Fans remained OFF between 15:48 and 16:31 (43minutes), triggering an orderly withdraw of all persons from the underground as per NG-VTL-SOP-349”Ventilation System Failure”.

OTHER INFORMATION/DETAIL: All personnel were safely withdrawn from the mine and accounted for. The main fans were restarted after 43minutes and the mine was pre-shifted as per SOP309. During the pre-shift no dangerous accumulation of methane were encountered.

Marlborough 20:10 (>4 hours)

14th March 2018

Structured Audit of the Principal Hazard Management Plan for Gas Monitoring

This Mine Record Entry is putting on record the information required, the purposes, structure and processes of the Structured Audit of the Principal Hazard Management Plan for Gas Monitoring and discussions between the Inspectors and the Site Senior Executive, Underground Mine Manager and Ventilation Officer.

The Audit will be conducted by Inspectors Marlborough, Brown and Gouldstone at a future yet to be set date.

This raises several questions

Did the Inspectors conduct the Audit prior to September 2018?
If so, did they provide the Mine (SSE, UMM, VO) with the Report prior to September 2018?
Were any Directives Issued as a result of the Audit?
Were any Substandard Conditions or Practice (SCP) Notices Issued?
Were any Recommended Corrective Actions (RCAs ) and Mandatory Corrective Actions (MCAs) issued?

Inspector Marlborough makes no mention of the Audit in any of his subsequent MRE’s.

Not even on the last Inspection on the 30th May.

10)

24/03/2018

TIME:

20:30

LOCATION:

NGC-10 South 2C/T

During mining in 2C/T 10 South Development panel intersected gas drainage borehole deviated from the plan. This has caused elevated levels of CH4 causing CM to trip at 2% CH4. The excess CH4 from the hole formed CH4 layers in excess of 2.5% between the face and the end of slider tube. The methane layers were diluted through the extended slider tube. The maximum CH4 flow through the fan was recorded at 1.5% CH4. Production was suspended pending further investigation. Men were withdrawn from the face area.

OTHER INFORMATION/DETAIL: The Pipe was reconnected through the stopping between shifts. All crews were informed about the incident.

John Kabel 09:17 (11 Hours)

11)

DATE:

05/04/2018

TIME:

23:30

LOCATION:

NGC-10 North 15C/T

During the regular inspection in the 10North Development Panel ERZ Controller found in 15C/T a CH4 Layer in excess of 2.5% due to removed CH4 discharge 4” pipe. The pipe was removed to spray the stopping to the required rating. Atr that time the operator thought that the line was isolated. Immediate ERZ Controller actions included isolation of the 4” CH4 pipe, layer removal by opening the man door and diluting the gas to the return roadway and inform shift supervisor of the condition found.

OTHER INFORMATION/DETAIL: The permit to Mine has been revoked pending investigation. All crews were informed about the incident.

Marlborough 13:09 (13 Hours)

12)

17/05/2018

TIME:

07:00

LOCATION:

9n TG 3 c/t

Sparks observed emitting from pneumatic roof bolter exhaust

OTHER INFORMATION/DETAIL: At approx. 7:00 2 x CMW’s pre-started the Super Turbo roof bolter serial number ST2094. They cleared the air line, connected to roof bolter and test run for 5 seconds. CMW heard something fail internally and sparks were seen emitting from bottom of the motor. Bolter was disconnected and did not feel hot. A third party supplier did an initial inspection of the machine and found the motor bearing had failed and could have been the source of the sparks. Currently trying to engage the OEM to investigate the design of the Roof bolter in relation to this sparking.

Scully 11:00 (4 hours)

13)

DATE:

26/05/2018

TIME:

07:29

LOCATION:

NGC-MG 10 Development Panel

In MG 10 Development Panel at 07:29am loss of power caused the stoppage of both bleeder road and installation road auxiliary fans and resulted in the buildup of CH4 levels exceeding 2.5% in GB.

The exceeded levels were noted during the pre-shift inspection conducted by the section ERZ Controller. To prevent an unauthorised entry both roadways were “no roaded”.

At the time of the finding no mining activities were conducted and no other personnel were affected by the CH4 buildup.

Marlborough 10:17 (<3 hours)

14)

DATE: 01/06/2018 TIME: 15:29 LOCATION: NGC-MG 10 Development Panel – Bleeder Road

In MG 10 Development Panel at 15:29pm loss of power caused the stoppage of both bleeder road and installation road auxiliary fans and resulted in the buildup of CH4 levels exceeding 2.5% in GB in the bleeder road.

As a result of loss of power all mining activities stopped. Electrical power was restored to the section transformer at 15:42pm following DCBs and Auxiliary Fans restart under NGC degassing procedure.

MRE 30/5/2018

1.1 Methane in excess of 2.5% in a development not reported as HPI

Inspector Marlborough had received a report from a complainant that an oxygen level of only 5% had been detected in a development with a suggestion that unauthorised personnel had ventured into the heading concerned. Discussions took place with an official involved which clarified without doubt what had occurred. There was a layer of Methane above head height which the official involved had used to demonstrate the hazards of such an atmosphere to the coal mine workers who were assisting with the degassing of the heading. Mr Romanski arranged to report the matter as a HPI. The detail will be added to the Mine Record and as such is available to any CMW at the Mine.

Inspector Marlborough stressed, for the sake of clarity, that any general body reading where methane exceeded 2.5% where controlled ventilation is required must be reported as an HPI. This is regardless as to whether or not people are withdrawn as a result of the gas. In this case where ventilation was lost because of power loss to the auxiliary ventilating fan, the brattice wing erected to provide an atmosphere < 2.5% methane had not been effective and as such was a failure of ventilation.

Further the barricading and signage to be provided where an irrespirable atmosphere was measured, albeit as a roof layer, must be of robust construction to prevent access inadvertent or otherwise.

Marlborough 19:50 (>4 hours)

15)

DATE: 05/06/2018 TIME: 02:06am LOCATION: NGC-MG 10 Development Panel – Bleeder Road

Loss of underground power at 04.27am caused the stoppage of both bleeder road and installation road auxiliary fans in MG 10 Development Panel and resulted in the buildup of CH4 levels exceeding 2.5% in GB in the bleeder road. As a result of loss of power all mining activities stopped.

Les Marlborough 06:44 am (>4 hrs)

16)

DATE: 06/06/2018 TIME: 04:27am LOCATION: NGC-MG 10 Development Panel – Bleeder Road

Marlborough 06:52 (2 hours)

17)

DATE: 12/06/2018 TIME: 00:31am LOCATION: NGC- 9North LW-TG

During the temporary production stoppage in the 9North LW face the CH4 level in the TG roadway spiked for four minutes above 2.5% reaching maximum value of 2.63%. The spike was caused by a large roof fall in the goaf.

Marlborough 14:56 (>14hrs)

18)

DATE: 19/06/2018 TIME: 08:00am LOCATION: NGC-MG 10 Development Panel – Bleeder Road

An accidental Section Transformer trip caused the stoppage of both bleeder road and installation road auxiliary fans in MG 10 Development Panel resulting in the CH4 buildup in the bleeder road exceeding 2.5% in GB. Due to shift change there were no mining activities carried out at the time of the power trip.

Reported Marlborough 16:34am (>8 hours)

16:34 same time 19th and 20th events. Is it a result of cut and paste?

19)

DATE: 20/06/2018 TIME: 08:00am LOCATION: NGC-MG 10 Development Panel – Bleeder Road

An accidental Section Transformer trip caused the stoppage of both bleeder road and installation road auxiliary fans in MG 10 Development Panel resulting in the CH4 buildup in the bleeder road exceeding 2.5% in GB. Due to shift change there were no mining activities carried out at the time of the power trip.

Reported Marlborough 16:34am (>16 hours)

20)

DATE: 24/06/2018 TIME: 06:15-AM LOCATION: 3C/T Corridor – LW Crib Room

A coalmine worker was pinned between CABA station located in 3C/T-Corridor LW Crib room and by rolling back Driftrunner 912 when the hand brake was released by the driver. An injured person was taken to the surface to be assessed by the site paramedic, and then taken to Mackay Hospital for further assessments.

21)

DATE: 23/07/2018 TIME: 08:50pm LOCATION: NGC-MG 10 Development Panel – Bleeder Road

Due to the damaged S/C cable power has tripped to the section TX. Loss of auxiliary fans resulted in the gas buildup of CH4 above 2.3% in the Bleeder Road in MG 10 Development Section. The Face road CH4 levels did not exceeded dangerous levels peaking at 0.74% at the highest reading.

Sullivan 03:30 am (>17 hours)

22)

DATE: 28/08/2018 TIME: 16:45 LOCATION: NGC-9N Tailgate seal #1

An inadvertent, rapid vent change resulted in a plug of methane purging from the goaf into the return general body.

OTHER INFORMATION/DETAIL: The rapid vent change pushed a plug of goaf gas into the TG return exceeding 2.5% for 13 minutes and #1 seal sampling triggered an orderly withdrawal under level 3 TARP36. After levels returned to Normal condition a risk assessment was conducted prior to re-entry

Marlborough 19:13 (2 and half hours)

23)

DATE: 31/08/2018 TIME: 13:48 LOCATION: NGC-Underground Workings

Due to the TARP 036 – 80% explosibility activation triggered an orderly withdrawal of all persons from the underground commencing at 13:20 and completed by 16:00.

All personnel were safely withdrawn from the mine and accounted for. Multiple updates given to each shift at least three times per each shift.

Marlborough 17:45 (4 hours)

24)

DATE: 01/09/2018 TIME: 15:02 LOCATION: NGC-Underground Workings

Due to the TARP 007 Level 4 activation triggered an orderly withdrawal of all persons from the underground commencing at 15:25 and completed by 17:00.

Marlborough 21:06 (6 hours)

All personnel were safely withdrawn from the mine and accounted for. Multiple updates given to each shift at least three times per shift.

MRE – North Goonyella – 03.09.2018.pdf

Mr Romanski gave me an update of progress during the night.

The planned ventilation change, closing down 1 surface fan, had occurred at 6:00 PM on 2 September. This was modelled at reducing the face quantity to 20 m/s with only 2 m/s reporting to the TG hatch.

Mr Romanski explained that these quantities could not be confirmed as people were not allowed underground.

NGC_HPI – NOTICE OF CONFIRMATION – Loss of Escapeway(2)-30.01.2017

NGC_HPI – NOTICE OF CONFIRMATION – Loss of Escapeway-31.01.2017

170711 a ventilation failure causing a dangerous accumulation of methane or other gas

170712 a ventilation failure causing a dangerous accumulation of methane or other gas

170903 a ventilation failure causing a dangerous accumulation of methane or other gas

NGC_HPI – NOTICE OF CONFIRMATION – Elevated CH4 Levels in TG-05.11.2017

NGC_HPI – NOTICE OF CONFIRMATION – Elevated CH4 Levels in LW 9 TG-NS-25-26 November 2017

NGC_HPI – NOTICE OF CONFIRMATION – Orderly Withdrawal 26.02.2018

180324 An event causing the withdrawal of a person from the mine or part of the mine

180405 An incident causing the death of, or a serious bodily injury to, a person

NGC HPI Notice 28-05-2018