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This document outlines the objectives and actions undertaken by the Plant Specifications Working Group to enhance safety standards in the UK opencast coal industry, particularly following the tragic Pennyvenie accident in February 2007, which resulted in two fatalities. Key initiatives include the development of technical standards, improved communication methods, and traffic management plans. It emphasizes collaboration with manufacturers, the Health and Safety Executive (HSE), and other stakeholders to promote consistent safety practices and mitigate future risks associated with heavy mobile plant operations.
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Plant Specifications Group – Objectives • Establish technical standards and specifications for the manufacture and operation of vehicles and mobile plant operating the UK opencast coal industry • Engage with plant manufacturers, the HSE and other external bodies to promote a consistent approach to plant specifications • Consider arrangements for the inspection and maintenance of vehicles and mobile plant and develop procedures to ensure that the risk to maintenance personnel is controlled • Liaise with other CoalPro working groups, particularly the Traffic Management Group to ensure that a consistent approach to vehicle safety is adopted
Largest surface mining company in UK • 3.5 million tonnes per year • 9 production sites • 900 employees • Plant fleet: - 29 prime mover excavators 122 dump trucks 172 other main plant items • Other interests – Land, Renewable Energy
Pennyvenie Site • Dalmellington, East Ayrshire • Operations commenced 1987 • 24 hour operation • 700,000 tonnes per year • 130 employees • Main plant – 6 x RH120 Terex TR100 Cat 777D
The Incident • 26th February 2007 at 1pm • 2 deaths Brian French (48) Foreman Fitter Colin Ferguson (37) Fitter • Multiple crush injuries caused by Terex TR100 dump truck colliding with Land Rover in dig area
What happened? • Fitters were clearing loading zone for non-critical inspection on RH120 • Fitters had no radio and were using hand signals • Land Rover drove past stationary dump trucks on off-side • Land Rover parked in Terex TR100 blind zone • Terex TR100 turned on full right lock • Operator continued to attempt to drive over obstacle following initial collision
Post Accident • Emergency procedures instigated • Preparations to move truck abandoned • Emergency services on site within 20 minutes • Police investigation • Scottish Coal detailed survey of area • Bodies recovered 10pm • HSE investigation • Reconstructions of incident (Scottish Coal + HSE)
Investigation Significant Factors Considered • Land Rover entered dig area before trucks were removed – supervisors not aware • No radio communication • Land Rover parked in blind zone • Truck driver not concentrating and reading newspaper • Truck moved away into blind zone on full right hand lock • Land Rover and truck same colour – no contrast • Truck driver trained but relatively inexperienced
Cab support Land Rover roof Line of truck bonnet
System Improvements • Radios in all vehicles • Traffic management plans - new rules controlling entry into dig areas • Supervisor’s vantage points • Segregated light vehicle routes • Buggy whips on all light vehicles • Off-side CCTV on all rigid dump trucks • Improvements to TR100 operator visibility • Training – MPQC Assessors and Instructors
Mirror 7 Mirror 4 Mirror 3 Mirror 5 Mirror 1 Mirror 6 Mirror 2 Off Side Camera
Supervisors Vantage Point Radio protocol
Consequences for SRG • 2 prohibition notices No entry of non-production vehicles into dig area No use of dump trucks without radios • Prosecution Sections 3 and 33 HSWA Fine - £400,000 • Fatal Accident Inquiry – 35 days in court • Civil claims – litigation ongoing • Substantial production, management and legal costs • Loss of reputation
FAI – Sheriff’s DeterminationsPrecautions which may have prevented deaths • Radio communication • If truck driver had paid attention and not been reading a newspaper • If truck had stopped after initial collision • Specific training/instruction to prevent full lock turn into blind zone and when faced with obstruction • Buggy whips • Off-side CCTV • Effective segregation of light vehicles and trucks
FAI – Sheriff’s DeterminationsOther relevant factors • Failure to learn lessons from 2005 incident • Greater emphasis required to alert operators to consequences of reading newspapers • Post-accident safety improvements were introduced voluntarily by Scottish Coal • Scottish Coal has performed a leading role in promoting safety within industry • Collaboration with HSE, CoalPro, QNJAC is important to ensure safety improvements are implemented • Improvements required to training and operator competence assessment schemes industry wide
FAI – Sheriff’s DeterminationsOther relevant factors • HSE to consider mechanisms for more efficient dissemination of best practice identified by inspectors • HSE should enquire about radio use and traffic management during inspections • Consider updating Quarries Regulations and ACOP to address issues - segregation, blind spots, radios • Engage manufacturers to ensure ongoing improvements • Develop industry practice for off-side CCTV and consider development of international standards • HSE to consider use of police crash investigators • Consider introduction of new RIDDOR Dangerous Occurrence category for vehicle incidents
