Agreed Facts
7 An Agreed Statement of Facts pertaining to both charges was tendered and relied upon by her Honour. The Agreed Statement of Facts was in the following relevant terms:
1. These proceedings were instituted with the written consent of the Director-General of the Department of Mineral Resources, who is a prescribed officer within the meaning of s 48 of the Occupational Health and Safety Ac t 1983.
2. Waratah Engineering Pty Limited ("the Defendant") is a body corporate.
3. Christopher Allen was an employee of the Defendant.
4. Christopher Elliott, Colin Bradley and Douglas Jones were employees of Powercoal Pty Limited ("Powercoal").
5. Powercoal operated an underground coal mine located near Dora Creek, 35 kilometres south west of Newcastle, on the western side of Lake Macquarie, which coal mine was and is known as Cooranbong Colliery ("Cooranbong Colliery" or the "mine").
6. At the mine mining was conducted by means of continuous miners. At all material times Powercoal had four continuous miners operating at the mine. The continuous miners were manufactured by Joy Manufacturing Pty Ltd ("Joy").
7. The continuous miners included machine 12 CM12 JM 4774. That machine was owned and operated by Powercoal.
8. Another continuous miner in operation at Cooranbong Colliery was a Joy 12 CM12 (No CM04) JM 4952 which was owned by Waratah Hire Pty Limited and hired to Powercoal pursuant to a hire contract for the purposes of producing coal. Waratah Hire engaged the Defendant to service it. Waratah Hire was a wholly owned subsidiary of the Defendant. It had one employee who was the manager of the company and simultaneously held the position of Operations Manager of the Defendant.
9. The Defendant employed service technicians who were required to service mining and other equipment (including the continuous miner) for various mining companies and for Waratah Hire. The Defendant owned and operated a workshop for that purpose and also sent its technicians to mine sites to work on mining equipment.
10. Christopher Allen was employed as a service technician.
11. On 5 March 1999 Christopher Allen was inducted to work at the mine at the Cooranbong Colliery and to perform work in accordance with instructions issued by responsible mine officials. Christopher Allen held no appointments from the mine manager authorizing him to operate any underground machinery.
12. On 30 June 1999 the continuous miner sustained damage to the conveyer boom main hinge points.
13. John Gluszek, another of the Defendant's employees, and Christopher Allen went to Cooranbong Colliery on 30 June 1999 and inspected the continuous miner. It was observed that the pivot tubes had broken out, that there were some fractured brushes and some other damage to the continuous miner.
14. Christopher Allen disconnected the conveyer boom from the continuous miner and it was taken to the Defendant's workshop for repairs.
15. On 1 July 1999 Christopher Allen was asked to go to Cooranbong Colliery to assist in the installation of the conveyer boom on the continuous miner. He was issued with a Job Instruction for Job 12732, ITP, parts and a material data sheet.
16. The job instruction included a direction to "isolate machine as per colliery instructions" and extracts from the maintenance manual for the machine CM04, JM4952.
17. The repaired conveyor belt was transported to the Cooranbong Colliery. The installation of the conveyer boom onto the continuous miner had commenced during the afternoon shift on 1 July 1999 and was being conducted approximately 125 metres below the surface and about 7.5 kilometres from the entrance to the mine known as storage B Panel. Christopher Allen assisted the afternoon shift in the installation.
18. Christopher Allen left the job and came out of the mine at approximately 9.30pm as there was no Deputy present. He was asked by Allan Tandy, from Powercoal to stay while the job was completed and he left the pit top at 10.30pm with the night shift to go underground again for a second shift for that purpose.
19. The night shift crew with Mr. Allen in attendance was required to complete the installation and specifically was required to connect the boom lift cylinders to the boom and reconnect the conveyer.
20. The fitter in charge was Christopher Elliott who was assisted by Colin Bradley, another fitter, and Doug Jones, an operator. All three held numerous appointments including an appointment to operate a Joy CM12CM on face operations during production.
21. Messrs Elliott and Bradley positioned the right hand boom lift cylinder and attached it to the bottom mounting point, the ram of the cylinder was extended by hand and attached to the underside of the boom with the clevis pin.
22. Messrs Elliott and Bradley attached the left hand lift cylinder to the bottom mounting point and attempted to extend the ram by hand. They were not successful.
23. Because they were unable to extend the left hand boom lift cylinder by hand Mr. Elliott decided to use the machine hydraulics. Mr. Jones was summoned from the crib room to operate the miner. Mr. Elliott instructed Mr. Jones to lower the stabiliser jack to provide more working room. Mr. Jones turned the power on and by using the remote control box lowered the stabiliser jack and turned the power off again.
24. Mr. Elliott climbed into a space between the underside of the conveyor boom and the stabiliser jack which was in the lowered position. Mr. Bradley positioned himself under the rear side of the continuous miner between the rear bumper and the floor adjacent to the left hand side of the stabiliser jack foot and held the cylinder foot in position with his foot.
25. Mr. Allen had been at the toilet during the connection of right hand boom cylinder. He returned and was present at the attempt to extend the left hand boom lift cylinder but gave no instruction or advice about the procedure being used, and took no personal part in it.
26. Douglas Jones started the power on the continuous miner with a remote radio controller the effect of which was to cause the stabiliser jack to be raised partially from its lowered position. The remote radio controller was in "radio" mode. The stabiliser jack retracted (i.e. rose) automatically when the machine was used in radio mode. This caused both of Christopher Elliott's legs to be trapped between the stabiliser jack and the underside of the continuous miner.
27. The procedure the Powercoal employees used to raise the boom lift cylinders using the machine's hydraulics accorded with the written procedures in the manual provided by Powercoal and published by the manufacturer, Joy, but differed from the procedures set out in the Waratah Hire manual. Those differences are set out below.
28. The automatic stabiliser jack retraction feature had been added to the Joy continuous miners in an effort to improve the safety of the machines and avoid the possibility of unpredictable and dangerous slewing of the conveyor boom on start-up with the stabiliser jack down. However, a Hazard and Operability Study of the 12CM12 continuous miners conducted in April 1998, in which both Powercoal and the Defendant participated, had recommended that this feature be eliminated.
29. Douglas Jones had been operating this particular continuous miner for 3 months and knew that the stabiliser jack had the capacity to retract automatically but had never changed the boom or lifted the boom jacks on this model of continuous miner. On three or four occasions he had changed the booms on certain other continuous miners but they did not have a stabiliser jack that retracted automatically. He was unaware of the isolation power rules. At all times he simply followed the fitter's instructions.
30. Colin Bradley was able to remove his right leg from its position between the stabiliser jack and the main frame of the continuous miner before the stabiliser jack first started to retract and was therefore able to avoid injury.
31. The continuous miner was immediately shut down using the remote control. Christopher Elliot's legs remained trapped. Mr. Jones restarted the miner with the intention of releasing Mr. Elliott's legs by use of the remote control whilst holding the stabiliser jack toggle in the down position. This did not override the automatic retraction of the stabiliser jack, which then retracted to the full up position. The effect of this was to further crush Christopher Elliot's legs.
32. Christopher Elliott's legs were crushed and the metal pierced his left thigh cutting through the femoral artery and vein ultimately causing his death.
33. Immediately after the second retraction the stabiliser jack was then lowered to the ground using the stabiliser jack toggle. This was possible as the machine had not been turned off as it had been on the earlier occasion.
34. The continuous miner operated in accordance with the machine specific software details as set out in the MCS Radio Specification Manual for the Waratah Hire Manual for CM12 JM4952. As the remote control, rather than manual mode, was used, the stabiliser jack of the continuous miner automatically retracted upon the hydraulic pump on the continuous miner being started. If the remote control had been in manual mode the stabiliser jack would not have automatically retracted. The software details were not included in the material supplied to Mr. Allen with the Job Instruction for Job 12732 and neither he nor any of the Powercoal employees was advised that if the remote had been in manual mode the stabiliser jack would not have automatically retracted.
35. It would have been possible after the initial retraction for Mr. Jones to immediately lower the stabiliser jack utilizing the stabiliser jack toggle had the machine not been turned off. As the machine was turned off the effect of powering up for a second time was to cause a further automatic retraction (this time to the full up position) in accordance with the software logic incorporated into the machine by the manufacturer.
36. The Defendant had access to the Waratah Hire Technical Manual for 12CM12 -12BVW, CM04 JM4952 written by Joy ("Waratah Hire Manual"). Extracts from this manual were given to Christopher Allen as part of his job instructions.
37. The Waratah Hire Manual recognised that the continuous miners had two modes of operation, radio and manual, and that radio mode was primarily used for production and manual mode was intended primarily for maintenance purposes.
38. Waratah Hire Manual contained the following instruction: "Check to be certain that everyone is well clear of the machine before moving it or adjusting the position of any hydraulic component." This section was not included in the material supplied to Mr Allen with Job Instruction for Job 12732.
39. The Waratah Hire Manual in the section dealing with replacement of the main conveyor provided that in replacing the conveyor the following steps should be followed:
. Isolate the miner electrically as per the Mine Managers Rules
. Extend conveyor lift jacks and install pins
. Reconnect hydraulic hose to the conveyor swing cylinder.
This section was included in the material supplied to Mr. Allen with Job Instruction for Job 12732.
40. The instructions in the Waratah Hire Manual did not require the hydraulic hoses to be reconnected prior to the cylinder being reconnected. The manual contained no instructions that conveyor or lift jacks are to be extended using machine hydraulics.
41. The manual used by Powercoal for the operation of the 12CM12 CM 04 was a different manual ("Powercoal Manual") which had been prepared for a different continuous miner that is machine JM4774.
42. The Powercoal manual differed from the Waratah Hire Manual in that it contained a recommendation from the manufacturer against manually operating the hydraulic functions and also suggested that "the radio remote facility allows the machine to be operated from the most advantageous position."
43. Powercoal had determined that radio mode was to be used for maintenance purposes and issued an instruction to that effect.
44. The replacement procedure for the conveyor set out in the Powercoal manual also differed from the procedure in the Waratah Hire manual in that it provided for the following sequence:
. be certain that electrical power has been disconnected
. reconnect the hydraulic hose to the cylinder
. reconnect the electrical power to the machine and carefully extend the cylinder hydraulically until the cylinder rod eye aligns with the pin bore in the mounting racket on the conveyor
. disconnect electrical power from the machine
45. These procedures necessarily required the hydraulic hoses to be reconnected to the boom lift cylinder before the cylinder itself is reconnected.
46. These procedures were duplicated in the Powercoal Job card JM019 that applied to the work being conducted by the employees of the mine, namely Messrs Elliott, Bradley and Jones.
47. The job instructions issued to Christopher Allen specifically directed him to "isolate the machine as per colliery instructions". The directions in the extracts from the Waratah Hire Manual provided to him also directed that the miner be isolated electrically as per the Mine Manager's rules. The mine manager rules on isolation were contained in Powercoal Isolation Procedures (GWP005) and Continuous miner Operating Procedures (SWP002). These procedures were not applied on the night of 1 July 1999. The Powercoal employees believed they needed the power of the miner to raise the hydraulic cylinder. They were not given a portable hydraulic jack although there was one available at the mine.
48. None of the Powercoal employees was given specific instructions by their employer or by Waratah Engineering about the method to be adopted to attach the boom lift jacks to the new boom or the safe way to elevate the boom lift jacks.
49. The safe working procedure ultimately adopted after the accident for completion of the task of connecting the left hand boom lift cylinder was based on the extracts from the Waratah Hire Manual provided to Mr. Allen with the addition of the instruction that the conveyor lift jack be extended "using auxiliary hydraulic power pack". This instruction was inconsistent with the instructions in the Powercoal manual and Powercoal job card JM019, which envisaged using the machine's hydraulics, but not inconsistent with the procedure in the Waratah Hire manual which did not. On the other hand the Waratah Hire manual did not advert to the method to be applied to extend the boom lift cylinders in the event that the task could not be carried out manually using an auxiliary hydraulic power pack.
50. None of the mine employees was (sic) conscious of or remembered the automatic retraction feature even though the mine itself had issued a written reminder to its fitters of stabiliser jack automatic retraction upon start up on 18 November 1998 after there was a near miss in similar circumstances.
51. Christopher Allen was not informed or instructed about or trained in the automatic retraction of the stabiliser jack upon start-up in remote mode arising from software incorporated in the machine and did not bring this feature to the attention of the employees of Powercoal: Christopher Elliott, Colin Bradley and Doug Jones. The Defendant did not take any other steps to bring this feature to the attention of Powercoal employees.
52. Consequently, the Defendant did not provide such information or instruction as may have been necessary to ensure that Colin Bradley and Christopher Elliot, persons not in its employment who were present at its place of work were not exposed to risks to their health or safety arising from its undertaking.