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Saltbush to Steel
The newsletter for employees and contractors of OneSteel Whyalla Steelworks and Arrium Mining
Issue 581 December 2014
A Christmas
Safety
Message
Acknowledging the signing of the first major operating contract by Walga Mining and Services are, from left, Walga Mining
Operations Manager, Ken Burton, Arrium Mining General Manager Development, Gavin Hobart, Chief Executive, Greg Waters, Senior
Manager Development, Ron Hardman, and Walga Mining Executive Director, Elliott McNamara.
MAJOR CONTRACT AWARDED TO
ABORIGINAL MINING BUSINESS
Arrium Mining has continued to strengthen its
relationship with the local aboriginal community,
announcing the signing of a major operating contract
with local aboriginal business Walga Mining and
Services.
Walga will provide crushing and screening; material
handling; and train-loading activities at Iron Knob which
will directly employ between 30-40 people.
According to Walga Mining Executive Director, Elliott
McNamara, this is a major milestone in the company’s
history.
“There has been a significant amount of work in recent
years to help give our company a start in business,
so we truly value and appreciate the support Arrium
Mining has provided in enabling us to achieve this
milestone,” he said.
“We are keen to demonstrate the capability of the local
aboriginal community in the mining industry, so this
contract presents us with the perfect opportunity to
achieve this.”
Arrium Mining Chief Executive, Greg Waters, said this
contract was a significant step forward in a relationship
that had been developing for many years.
“A particularly strong relationship has been forged by
working closely with the local Barngarla people to reestablish mining activities at Arrium Mining’s Iron Knob
operations,” he said.
“This has seen the signing of an Indigenous Land Use
Agreement covering the Middleback Ranges Mining
area, incorporating Iron Knob where Walga will be
operating.
“The Iron Knob region is rich in aboriginal heritage
sites, so we would like to acknowledge the support
of the Barngarla people to date in supporting the
recommencement of mining in the area.”
The contract – which was signed in late September – will
see Walga mobilise to the Iron Knob site in December,
with full operations commencing in January 2015.
It’s that time of year
once again when we
all start focusing on
Christmas and looking
forward to spending
time with our friends
and family. While it’s
great to have these
things on our mind,
it’s vital we ensure
they don’t become a
distraction at work.
Please ensure you
remain focused on
doing each and every
task safely so that
this Christmas doesn’t
become memorable for
all the wrong reasons.
For those having
time away from the
workplace, safety in
the home is just as
important. This time
of year can involve a
variety of potentially
dangerous activities
such as driving long
distances; consuming
more alcohol than
usual; and undertaking
home renovations.
Please ensure that
you keep the safety of
yourself, your loved
ones and your friends
at the forefront of
everything you do, so
we can all return to
work safely next year.
Have a fantastic
Christmas and New
Year, and we’ll see you
all back safely in 2015.
2
3
OUR BUSINESS / OUR SAFETY
OUR BUSINESS
STEELMAKING YIELD IMPROVEMENT
PELLETISING AWARDED HONOUR
AT WORLD DEMOLITION AWARDS
The Pelletising Redundant Equipment
Dismantling Project has been recognised
at the 2014 World Demolition Awards in
Amsterdam being awarded “Contract of the
Year < US $1.5 million”. The project received
the nomination by contracting company
Australian Decommissioning Services
(AusDecom) and was awarded the accolade
over demolition projects worldwide, including
throughout the United States and United
Kingdom.
From left, Michael Grubb, Fungai Paraiwa, Jari Peltonen, Israel Murgas, Robert Wiblen, Thanh To, Nico Oosthuizen, Chris Thompson, Walter Aitken andJeff Dykes.
In March 2014, Steelmaking identified
yield improvement as one of its biggest
focus areas. From there a project team was
established to focus on yield loss, as even
1% of yield loss can result in significant costs
to the business. Over the past nine months,
Steelmaking have had some significant
results with yield improvement increasing to
86.2% - a net improvement of 0.8%.
One of the issues identified was the
decanting of steel from ladles which occurs
when overfull ladles do not have the
required freeboard for a safe operation.
This was resulting in a 0.2% yield loss and
a significant monthly plant damage bill. The
team used six sigma tools to identify the
variables affecting the level of decanting. By
acting on these variables, a 50% reduction
in decanting was achieved. This had a 0.1%
positive contribution on the yield figure.
It was also discovered that teeming crane
1 was overstating empty ladle weight - an
issue which the electrical team was able to
resolve by fixing the load cell configuration.
This enabled the realisation of better weights
and yields per heat by having an accurate
measuring system.
The Yield Project also improved the
measuring system at the billet caster. This
also improved the rolling mill yield, with the
Sydney Bar Mill managing to achieve a 6.1%
yield improvement.
Overall, the Yield Project has proven to
be an excellent initiative for Steelmaking.
Its success is the result of a variety of
subject matter experts working together,
including melters and furnacemen managing
the furnace profile; engineering and
maintenance fixing the weighing systems
and providing reliability; BOS technical and
operations working on the yield initiatives;
and Caster technical and maintenance
working on the billet length initiative and
overall plant availability.
REHEAT FURNACE UPGRADE
The Reheat Furnace upgrade project is currently being undertaken
by the Capital Project Team in conjunction with project
representatives from Steel Products. The aim of the project is to
provide automation of the furnace material management system
(charging, walking and extraction of hot blooms) as well as a
significant reduction in the energy consumption of the furnace
(measured in GJ per tonne of blooms charged). The furnace
upgrade works will be delivered over two extended shutdown
periods. The first shutdown (currently in the final stages of
commissioning of the automation system) has seen the installation
of the furnace material management system – including a new
charge wall and door, modifications to the pusher machine and
modifications to the charging water cooled skids – along with a
new combustion air fan and recuperators to pre heat the furnace
combustion air. The new recuperators are delivering combustion
air temperatures of more than 400 degrees C – this was previously
less than 200 degrees C – providing a significant fuel saving for the
operation of the furnace.
With the shutdown construction works completed safely, the team
is focussing on integration of the new materials management
system into the existing control systems to ensure a seamless
operator experience. This work is being completed by SMS Meer – a
respected furnace design company – who were also responsible
for the design and supply of all materials and systems required to
complete the furnace upgrade.
The project scope included the removal of
the Grinding Mill Feed Conveyors, Black Hole
Bins, Dryer, Dryer Conveyors and Plinths.
AusDecom were engaged as the principle
contractor for the dismantling works, with
the selection based upon safety track
record and cost effectiveness. The project
team implemented a comprehensive safety
management system to undertake the
high risk work, which included safety and
environment management plans, detailed
pre-start toolbox meetings, specific safe
system of work documentation and detailed
engineering assessments of major lifts. To
test the quality of the planning and execution
of this task, personnel were invited from
across the business to conduct safety
observations and audits.
Project Team: Raymond Oaten, Chris Whitting, Peter Engelke, Sandeep Sharma, John Beinke, Brett
Osborn.
Dismantling site - June 2014.
AusDecom mobilised to site in May
and completed the dismantling work in
September with no injuries, two minor
safety incidents and minimal impact on
the operations and community. Successful
SWEAR BY SAFETY
As you may be aware, we are embarking on a journey to become
world-class in safety. As part of this, we recognise that rather
than focusing solely on systems and processes, our next phase is
to realise the potential of our individuals and their importance in
the future of our overall safety culture.
With this in mind, we are embarking on a campaign known as
‘Swear By Safety’ as a way of emotionally engaging our people
in the critical role that they each play in developing this worldclass safety culture.
Dismantling site - September 2014.
execution of the dismantling work couldn’t
have been possible without the support of
the Pellet Plant Operations, Maintenance and
Engineering teams.
ENERGY AWARENESS
CALENDAR
In the last Saltbush to Steel edition we ran a competition for kids
to design a 2015 energy awareness calendar. The response to
this competition was overwhelming with 70 entries across the 12
monthly themes with five winners coming from Whyalla. Each of
the winners received a $50 Coles/Myer voucher, certificate and
copy of the calendar. All runners up received a $10 Coles/Myer
voucher, certificate and copy of the calendar also.
A really big thankyou to everyone who participated - your efforts
are truly appreciated!
Although we will be driving the campaign, we are also aiming to
see the broader Whyalla community adopt ‘Swear By Safety’ and
its values, helping create a personalised, ‘whole-of-community’
approach to safety that’s integrated into everything we do.
You’ll start noticing this symbol – and the
The first bloom charged into the upgraded furnace.
The second stage of the project will see a new combustion system
installed on the furnace, including new combustion air and gas
pipework, new high efficiency burners, a new roof and side walls at
the discharge end of the furnace, a new discharge door and a new
combustion management (process control) system. The second
stage is currently scheduled for installation during a shutdown
planned to commence in June 2015.
colour yellow – appearing throughout
our operations and the community as we
gradually implement the campaign. If you
want to find out more, or are interested in
how you can get on board, please contact
our Project Coordinator, Daniela Dean, on
8640 4106 or 0404 178 088.
The winning local entries (clockwise from top left): Lauren Dempsey, Mary
Simpfendorfer, Amaya Middleton, James Darvall, and Ella Patterson.
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4
OUR SAFETY / OUR ENVIRONMENT
OUR SAFETY / OUR PEOPLE
AN EXCELLENT SAFETY INITIATIVE
SETTING THE
SAFETY BENCHMARK
A Southern Iron contractor has gone above-and-beyond to help
improve safety for his fellow fitters after a recent incident. Fitters had
used ‘home made’ tools and a hammer to replace ‘S’ cam bushes on
axles, however this practice recently resulted in a fitter lacerating his
finger and requiring five sutures.
Caster Shift Team Leader Craig Dahlin has been recognised as one
of South Australia’s most successful safety achievers, winning an
individual category at the 2014 Safe Work SA Awards.
Judges for the awards were impressed by his creative and effective
solutions for managing risk, which they rated as ‘above and beyond
the requirements of his role’.
Industrial Relations Minister, John Rau, congratulated the winners on
the night and said they set a standard that other businesses should
aim for in work place safety.
“Fundamental to each winner’s success is a positive work health
and safety culture and an attitude to safety that is instinctive, not
instructive,” he said.
As well as Craig, the Steelworks were also represented by two other
finalists – Steel Products’ Victor Lemmon and Eric Vines – while
Arrium Mining was also represented by Southern Iron’s Marco Criado
and contractor partner BGC.
OneSteel Whyalla Steelworks Caster Shift Team Leader, Craig Dahlin, left,
receives his award for winning the Best Individual Contribution to Work
Health and Safety category from Member of the Legislative Council, Kyam
Maher, at the recent Safe Work SA Awards.
According to General Manager Whyalla Steelworks, Theuns Victor,
to have so many finalists out of a record number of nominees from
throughout the State was an impressive result.
“This comes on the back of our success at the recent Australian
Steel Institute’s National Health and Safety Excellence Awards, at
which our ‘Rail Handling Equipment’ initiative – implemented by Noel
Goldsworthy and Greg Hancock – won the Improvement Initiative
Award, while Central Engineering’s ‘Forklift Exclusion in the Workshop’
initiative was highly commended in the same category.
“On top of this, to have Craig named a winner and Victor and BGC
receive a commendation is a fantastic reflection of our ongoing
efforts to be world-class in safety,” he said.
“I would like to extend my sincere congratulations to all of these
winners and finalists – they are perfect examples of how we can all
help ensure that we continually improve our safety performance.”
With no suitable tool available for this task, Qube Workshop Fitter,
Alastair Falland, designed and manufactured a tool at home in his own
time. His design included a welded heavy duty plate steel box frame
with a spring return cylinder. The cylinder is bolted to the inside of the
steel box and a porta-pack is attached to the fitting. A second fitter
controls the porta-pack pressure. Alastair also manufactured two
saddles – one to push the old bush through the cam and the other to
insert the new bush.
The tool has replaced the various risky devices used, allows both
hands to be kept out of the line of fire, and has been included in
the updated SWMS as the standard tool for the task. The tool also
has potential for wider use within Qube where this level of work is
undertaken on trailers.
Congratulations to Alastair for bringing added safety to his workplace.
The hammer, socket extension and steel tube used at time of injury. Inset:
The new tool which has greatly improved safety.
WHYALLA HELPING EDUCATE ALL OF ARRIUM
Arrium Mining and OneSteel Whyalla Steelworks employees will be
helping to educate all Arrium employees on the dangers of electricity
after starring in the new ‘Living Safely With Electricity’ video.
Central Engineering has recently celebrated 17 years LTI free. This is a significant achievement considering that approximately 5 million man-hours were put in
over this 17 year period. Engineering Manager, Peter Rostig, believes that “the continual drive and rigour around Safe Systems of Work, training and education
of the workforce have all contributed to the result. While this is a great milestone, we cannot rest on this achievement and must keep challenging and applying
rigour to continue our safety journey.”
The video was shot at the Whyalla Steelworks and SMR operations and
will gradually be rolled out across all of Arrium’s operations.
It’s part of an overarching ‘Living Safely With Electricity’ program
created by the Arrium Electrical Safety Network (AESN) to address five
common root causes of electric shocks in Arrium.
REDUCED MARINE DISCHARGE SEAGRASS IMPROVEMENT
A vital element of the Whyalla Steelworks is
the Cokemaking operation. However, as well
as producing coke, the process produces
nitrogen-rich water as a by-product, some of
which is discharged into our tidal embayment
leading into False Bay. Historically, the excess
nitrogen in this discharge had an adverse
effect on the seagrass within the area.
The video demonstrates how certain common electrical hazards can
be present not only at work, but also in the home. The good news is we
can manage these hazards well by following some guidelines, which the
overall program addresses.
Here are some key statistics as to why safety around electricity is
so vital:
•
In Arrium, on average someone gets an electric shock every
two weeks
•
In Australia, 20 people die every year from electrocution. Half
of these deaths occur outside work. 75% of them are nonelectrical people
•
In Australia, over 600 people every year are hospitalised due
to electrical injury, again mostly non-electricians
•
The root cause themes for electric shocks in Arrium are the
same common themes we see in Australian statistics
This program is currently being rolled out across the Whyalla
Steelworks, with other businesses to follow, and the video itself can be
found on the homepage of the Whyalla intranet or by searching ‘Living
Safely With Electricity’ on YouTube. We will also be making it available
to the general public to help educate the community on the importance
of living safely with electricity.
If you are interested in finding out more, or how you can help roll out
the program in your area, please contact Sean Kelly on 8640 4206.
From the mid-1970s through to the mid1990s, a series of pond systems and a
sea wall were installed to help retain this
discharge prior to entering the bay. This
created an embayment where natural
processes reduced the available nutrient
discharge load.
To provide an additional reduction in the
level of nitrogen discharged, a reed bed
treatment system was installed on-site in the
late 1990s. This system treats a portion of
the discharge which allows it to be reused in
the Coke Ovens process.
The video highlights how electricity can be a hazard both at home and at
work, as Molly Kroll (top), and Stuart Watt and Shane Sowerby (above)
demonstrate in stills from the video.
This load reduction, combined with the
natural processes occurring within the
embayment, have not only resulted in an
improvement in seagrass condition, but also
an expansion in overall seagrass in the area.
The expansion of sea grass between 1990 (left) and 2012 (right).
After consultation with the Environment
Protection Authority, in December 2012
OneSteel completed an extensive study
into the remaining Cokemaking discharge,
its impacts and the receiving environment.
This included a detailed assessment into the
recovery of seagrasses in the Upper Spencer
Gulf which had been historically impacted
by the nutrient discharge from the Coke
Ovens, as well as modelling of our discharge
and quality of water in False Bay. The study
has shown that adjacent to the Steelworks
the impacted seagrass has undergone
at least a five-to-ten times expansion in
extent between 1990 and 2012. In addition
to the expansion, the health of seagrass
near the discharge point is closer to that of
background sites in terms of leaf length and
biomass than was previously known.
The study findings are now guiding further
monitoring work that is currently being
designed, and once again in consultation with
the SA EPA. The aim is to further quantify
the continued improvement of the seagrass
and assess ongoing control measures.
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OUR PEOPLE / OUR COMMUNITY
OUR PEOPLE / OUR COMMUNITY
INSPIRING YOUNG
WOMEN TO EXCEL
Arrium Mining Shipping Manager, Hayley Perkins, has been
recognised for excellence – being named in the top five in the recent
Women in Resources National Awards. Hayley began her career in the
industry as an administration trainee, before working her way up to
her current management position. She was chosen as a finalist in the
‘Exceptional Young Woman in Australian Resources’ category after
impressing the judges with her efforts both in and outside of work.
CODES OF PRACTICE
Hayley accepting her finalist certificate at the recent Women in
Resources National Awards in Brisbane.
FRONTLINE LEADER
GRADUATION
The latest group of Leading Edge participants recently completed
their Frontline Management program, facilitated by Denise Archie
from Coaching College. Leading Edge focuses on developing
individual leadership skills and style through the implementation
of a project aimed at solving a work dilemma to impact workplace
cultural change and have a measurable ROI solution.
FIRST OSAND EVENT
The first OneSteel and Arrium Network Development (OSAND) event
was recently held at the Westland Hotel. General Manager of Mining
Operations, Matt Reed, and General Manager, Whyalla Steelworks,
Theuns Victor, presented a business update and shared some insight
into their own career journeys which included some valuable tools
for personal and professional development.
HR Manager Arrium Mining Operations, Deirdre Allen, was MC for
the program for the final time before taking on her new role with
Steel. Deirdre was acknowledged for her commitment and integral
support of the program over the years. Those taking part in the
program included participants Ben Izzard, Dale Clark, Dave Caldwell,
Mat Blott, Matt Stanton, Mike Hayes, Paul Vereyken, Robertson
Reupana, Thane Burdon and Haydn Meyers; and mentors Chris
Whitting, Deirdre Allen, Ron Hardman, Jacqui Higgins, Craig Wilson,
Louis Haarhoff, Dirk Vermooten, Mike Bannear, Michael Ewing, Geoff
Eri and Jarrod Mutton.
We were once again major supporters of the Pride in the Park event,
celebrating the community’s pride in its city. We also provided in-kind
support to the event, with Steelworks employees Felicity Adler, left, and
Lucy Ristivojevic volunteering their time to help out at the Rotary
food van.
Pelletising apprentice Shari Hunt, top, was recently recognised for
her excellent work, winning Apprentice of the Year at the Whyalla
Chamber of Commerce’s Annual Dinner. Central Engineering
The 2014 Leading Edge participants and mentors.
apprentice, Tara Pinski, above, was also named runner-up.
MATHEW STOKES’ VISIT
Indigenous AFL player Mathew Stokes visited our operations recently to
learn more about our businesses, including our work with local indigenous
groups. As part of the visit, we also took him out to local schools to meet
with indigenous students and talk about his life journey and the importance
Mathew Stokes with the Port Services Team.
The Steelworks Leadership group recently
launched the revised codes of practice, focusing on
Prevention of Falls, Electrical Safety, Cranes and
Lifting and Mobile Equipment. This was a practical
session run to develop deeper understanding of
how the codes are applied on the Steelworks Site.
The session included ‘The Greatest Pitch’ – a series
of posters designed to help our leaders engage
everyone on why the codes are so important to
us. A big congratulations to the team that won
‘The Greatest Pitch’ - Grantly Hamilton, Stephen
McAlister, Graham Eagles, John Tsalapatis, Dave
Evans, Andy Mitchell, Mark Eaton, Allen Gurnett,
Kate Spencer, Natalie Ward, Debbie Aspey and
Amanda Bywater. If you see their ‘Greatest Pitch’
shirt then give them a high five!
of staying in school to realise their potential.
Representatives of Foodbank, OneSteel Whyalla Steelworks, Arrium
Mining, Whyalla City Council and numerous local schools recently
celebrated the official launch of Foodbank’s School Breakfast Program.
The program assists local students who are attending school without
having accessed a healthy breakfast – ensuring they have sufficient
nourishment to start their school day. This helps set them up for success
and provides them with a better chance of success at school.
Photo courtesy of Whyalla News.
After the presentations, the attendees participated in a quiz night,
which proved to be enjoyable for all and a good opportunity to test
everyone’s knowledge. Congratulations to the “Pit to Port” Team,
who came first.
Overall the evening was a big success and OSAND are already
making preparations for the next OSAND event.
Winning the quiz at the inaugural OneSteel and Arrium Network
Development event were, from left, Frankie Tsang, Chris Ferdinands,
Jay Shi, Samar Maker and Kate Spencer.
Iron Knob residents,
tourists and Arrium
Mining representatives
are pictured at the official
reopening of the Iron Knob
tourist lookout. The town’s
most popular attraction
had been closed due to
safety concerns, but an
extensive upgrade now
enables tourists to get a
unique look at not only
the historical areas of the
mine, but also the current
operations in action.
8
OUR PEOPLE - CELEBRATING CAREER MILESTONES
From 1st September to 31st December 2014 the following employees
reached milestones with OneSteel and Arrium Mining:
35 YEARS OF SERVICE
James Huish, Daniel Kloosterman, Martin Hilton, Stephen Barnard
Sayouth Sysouphat, Peter Vincent, Alexander Corr and Ian Davies.
20 YEARS OF SERVICE
Wolfgang Schneider and Shane Fiedler
10 YEARS OF SERVICE
Wayne Evans, Warren Dunn, Daniel Vonk, Steven Hall, Brian Wohling
25 YEARS OF SERVICE
Paul Zoppi, Steven Pyett, Damian Grimm, Matthew Welk, Daniel
Dale Bristow, Peter Staunton-Smith, David Oliver, Simon Jones
Garry Goldsworthy, Christopher Wagner,Simon Raneberg, Gary
Coulson, Andrew Isaacson, Paul Utting, Darren Bartel, Stephen
Clarke, Jamie Sutherland , William Oberthur, Drago Garma, Mark
Peatfield, Darren Percy, Michael Hickey, Nicholas Kogos, Peter
Richardson , Lawrence McLean, Adrian Franks, Joseph Ramke,
Andrew Treacey, Mallar Mukherjee and Edward Colquhoun.
Schmidt, Jaryd Maxwell, John Nolan, Michael Wheeler, Roger
A special function was held for several past employees to
commemorate 50 years of the Steel Products department.
The retired employees were also taken on a tour of the
Steelworks. Pictured at the function are, from left, Scott
Howard, Bob Rudd, Steve Sheehan, Niel Simpson, Francois
Van Zyl, Barry Richard, John Bachmann, Kevin Boyle,
Ryan Andrew, Daniel Schmidt, Ben Liffner, Barry French,
Bill McKenna, Rod Grimm, Michael Leach, Ian Harvey, Jim
Cochrane, Bob Pitts, Alec Jackson, Leon Bastian. Seated:
Noel Klobucar, Mario Hrvoj, Irene Hrvoj, Tom McGowan,
Tom McQueen, Tubby Sowerby, Trevor Hopgood and
Richard Cass (on the floor).
Franklin, Ashley Gardiner, John Horner and Paul Mcnaught.
Contact us: We welcome your input to our newsletter. If you have
contributions or suggestions, contact Tiffany Ley on p: 08 8644 5710 e:
[email protected]
Principal Advisor Safety Systems Management, Deb Aspey, left, and Senior Advisor
Emergency Services and Injury Management, Rick Santucci, right, recently celebrated 30
years and 40 years of service respectively. They are pictured with Manager Safety Whyalla
Steelworks, Daniel Schmidt.
Production Operator, Danny Vonk, right, receives his 10year service award from Rail Plant Leader, Allan Wisbey.
General Manager Whyalla Port, Jon Hobbs, (front, third from right), was recently farewelled
by employees from throughout the OneSteel and Arrium businesses. Jon started with
OneSteel in 2004 as Director Project Magnet, then took on the role of General Manager
Manufacturing before overseeing the Whyalla Port Expansion Project. Jon will still be
working within Arrium, taking on the role of President - AltaSteel, based in Canada.
Steel Products Off Line Coordinator, Drago Garma, recently
celebrated 25 years of service.
Contracts Administrator, Lawrence McLean, centre, is congratulated on 25 years of service
by Contract Management Lead, Rose Range, left, and Contract Manager, Stuart Boath.