A loss of communications on an autonomous circuit at a BHP Mitsubishi Alliance's Goonyella open pit coal mine in Queensland in August last year led to the autonomous truck hitting the manually-operated excavator.

After the communication breakdown occurred, the excavator operator grounded the bucket and exited the cab.

While moving back to re-enter the cab, communication was restored. A Caterpillar truck, operating in autonomous mode, had been spotted into position started reversing toward the excavator and ultimately hit it.

The coal mine worker was unable to move the boom out of the way in time resulting in damage to the stick cylinder.

The Queensland Mines Inspectorate said there were no injuries to the coal mine worker.

The inspectorate said site senior executives should review start-up procedures after communications outages.

As far as Australia's Mining Monthly can determine there has never been an autonomous truck-excavator collision in Australia, and possibly in the world.

In many cases mines try to keep autonomous and manned equipment separate. The excavator is the exception because no original equipment maker has been able to successfully automate the loading function so there has to be an operator in the cab.

There is also the fact that the excavator is usually the largest beast in the pit and can take care of itself, which proved to be the case in the Goonyella incident.

Effective systems

RSHQ chief inspector of coal mines Jacques le Roux told AMM that the Goonyella incident did not involve any defects in the equipment being used.

"Queensland legislation places obligations on coal mine operators to effectively manage risks to worker safety in their mining activities," he said.

"This includes ensuring they develop effective systems and procedures appropriate to their specific circumstances.

"It's the operator's responsibility to work with equipment manufacturers on risk controls like proximity detection.

"RSHQ then audits the systems and procedures that mines have in place."

Le Roux said RSHQ's safety notices and monthly periodicals were part of the process to educate the industry about new developments and create a cooperative approach towards safer autonomous vehicle operation in the future.

‘Concerned'

Mining and Energy Union industry safety and health representative Jason Hill told Australia's Mining Monthly that the union was "very concerned" about an autonomous vehicle reversing into an excavator while a mineworker was in the area.

"The incident shows a failure in safety systems that left a mineworker exposed to serious harm after a communications failure and system reset," he said.

"Times of transition in mining technology can be dangerous to workers."

Hill said Queensland's Coal Mine Safety and Health Act needed to be updated to reflect the risks posed by the introduction of autonomous machinery to the industry.

"People operating machinery remotely, whether on or off-site, need clear guidelines about starting up machinery safely," he said.

"No vehicle, autonomous or otherwise, should be operating when there is a mine worker on the ground in the area."

Hill said the union is in constant dialogue with the government and regulator about safety in the mining industry, including in relation to automation.

Safety review

A spokesman for the Western Australian Department of Mines, Industry Regulation and Safety said it could not comment on the Goonyella incident or reach any conclusions as there was not sufficient information available at this time.

However, a review process is taking place on the issue of safety and autonomous vehicles in WA.

WorkSafe chief inspector of mines Martin Ralph told AMM that in 2015, Worksafe Mines Safety published a world-leading code of practice: Safe mobile autonomous mining in Western Australia. 

"The code is currently being reviewed to align it with WA's work health and safety legislation and to account for changes in technology," he said.

"Worksafe Mines Safety holds regular discussions with mine operators, original equipment manufacturers and international standards/guidance groups to keep track of autonomous systems of work. 

"Our aim is to deliver better safety outcomes by continually improving the application of autonomous technology on WA mine sites."

That standard was replicated by the Canada-based Global Mining Standards and Guidelines Group.

WA senior mines inspector Peter O'Loughlin - who has been instrumental in implementing the regulatory regime of autonomous vehicles in WA - told a mining conference that he firmly believes a non-prescriptive regulatory approach is the best way forward.

"We believe a risk-based regulatory approach will allow for the continued development of autonomous systems in both the surface and the underground," he said.

"We encourage the move towards zero entry mining.

"To me the risk-based approach is it."

The WA code of practice highlights the need for risk evaluation and management.

"Mobile autonomous mining, like any large-scale mining activity, is hazardous with many inherent risks," it states.

"When integrated with a manned mining operation, additional risks may be present beyond those recognised for conventional mining techniques.

"All hazards related to mobile autonomous mining need to be identified and controlled."

This is best done by applying the hierarchy of control.

"Higher-order control measures eliminate or reduce the risk more effectively than administrative controls or personal protective equipment," the code of practice states.

For mobile autonomous mining, it advises mine operators to implement primary controls that prevent and manage based on established processes and relevant standards, including separation of the autonomous fleet from manned operations where possible.

Risk management

About 80% of Rio Tinto's haul truck fleet across its Pilbara sites in WA is also autonomous.

These trucks, which use pre-defined GPS courses to automatically navigate haul roads and intersections, allow it to move more material, more efficiently and safely, increasing productivity.

It also continues to expand its Autonomous Drilling System and has a fleet of 32 production drills across seven sites. ADS allows the company to monitor multiple drills from different manufacturers across multiple sites from remote drill consoles in Perth.

A Rio Tinto spokeswoman told AMM that the company's focus was on identifying, managing and, where possible, eliminating risks. 

"We use automation and robots to do some of our high-risk work," she said.

"And we are focused and committed to strengthening our partnerships with industry and associated committees, contracting partners and local communities with the priority of learning and sharing to protect everyone's health, safety and wellbeing.

"Rio Tinto already has proximity detection systems for its autonomous haul trucks in place to alert passenger vehicles and autonomous haul trucks will stop automatically if they detect a passenger vehicle approaching."

A Fortescue spokeswoman told AMM that the company was a global leader in the use of autonomous vehicles with more than 220 autonomous vehicles operating across its mining operations.

This includes a combination of autonomous haul trucks, drill rigs and light vehicles.

Fortescue helped develop Caterpillar's Minestar autonomous haulage system.

"Our autonomous fleet operates within controlled environments where access is restricted to specially fitted vehicles and to personnel who have had relevant training to operate these vehicles inside the autonomous zones," the Fortescue spokeswoman said.

"Our autonomous systems all have additional equipment that is typically fitted on staffed vehicles, which allows this equipment to safely interact with, and navigate around, autonomous vehicles.

"Fortescue engages closely with the regulator to ensure our autonomous operations have the highest possible safety standards in place."