Development of Health &

Safety Management System in

Contractual Mining

Compiled by

S N MathurFormer GM (LP) GMDC & ED (Mines) GIPCL

Currently Independent Mining Advisor & Consultant

[for Seminar in Kutch, 3rd November 2012]

Increased demands Economy Growth

Faster Extraction of Minerals

(Coal & Lignite)

Uneconomical & Unviable Deposits

Heavy Mechanisation with Large size Hyd. Shovels &

Dumpers

New Technologies like

Highwall MiningIn-pit Crushing

Conveyors

Gujarat India

Depth 100 to 120 m 250 to 300 m Stripping Ratio up to 1:12.5 >1 : 15

Dump Heights up to 50 m + 120 m

250 to 300 m Excavators 4.5 m3 30 m3

Dumpers 50 Tonne 280 Tonne

Production 8 mTPA 60 mTPA

250 to 300 m

Departmental Mining

Short TermContract

Departmental Mining

Short TermContract

Long TermM D O

The Challenges for the Mining Contractors / MDOs:

- Infrastructure for maintenance and operation of Large HEMM;- Compatible Infrastructures; e.g. Haul Roads and Benches; - Customized Training and HR Capacity Building Plan;

- To understand, Design & Executive Mining Plans / Schemes - Problems of Pit and Dump Slope Stability;

- Mining related Statutes, Greater Importance to the Safety ;- Mine Environment : Dust, Noise and Vibration Control;

- Latest Information Technology and Communication systems;- Effective Emergency Response Mechanism at Mines; etc.

Contractors’ Responsibilities:

a) Safe Operating Procedure (SOP), including risk assessment

b) Ensure that all sub-contractors comply with the requirement Vocational Training and Initial & Periodic Medical Examination of all persons prior to deployment.

c) Issue cards stating the name of the contractor and the work and its validity period, indicating status of VT & IME.

d) Every person deployed must wear safety gadgets

e) To submit to DGMS Returns - Quarterly (by 10th of April, July, October & January)

Other Recommendations: With the increased scope of work, some of the recommendations of IX & X Conferences, which were supposed to be complied by the Mine Management, will now be expected to be within the scope of the Contractors, particularly in the scope of the MDOs.

The Contractors / MDOs have to learn to share these responsibilities, willingly or under the pressure of penalties and the Mine Managements have to ensure that these form the part of the Tender Documents / Contract Agreements.

1. Occupational Health Surveillance:

a) To establish Occupational Health Services as recommended by 7th Conference,

b) The frequency of PME: Three years for employees +45 yrs age.

c) Once a year Eye Refraction Test Employees engaged in driving/ HEMM operation jobs should

d) To set up a Periodic Medical Examination (PME) Centre with - the facilities for chest radiographs & lung function tests,

- arrangement for classification of chest radiographs and - also wherever required facilities for audiometry.

e) Chest radiographs to be classified for detection, diagnosis and documentation of pneumoconiosis in accordance with ILO classification for pneumoconiosis.

.

f) Computerisation of all records of medical and Environmental surveillance.

g) The PME Medical Officer to be trained in occupational health and use of ILO classification for pneumoconiosis

h) Noise mapping of machines used in the mine, - personal noise dosimetry of workmen exposed to noise level above 85 db(A).

i) Prior to introduction of machinery in mines: - Vibration studies, - Ergonomical assessment of all machines, to include:

* Assessment of work process.* Assessment of working Aids/tools* Assessment of working posture

j) Potability tests of drinking water supplied to employees, once in a year irrespective of its source, preferably after Rainy seasons

2. Quality Control for Improving Safety:

a) Setup Quality Control Cell for quality assurance of critical items, b) To notify authorities promptly any defect or failure of approved items or those having BIS certification, for further action.

3. Increasing Effectiveness of Worker’s Participation in Safety Management: a) Appointment of Workmen’s Inspectors. b) Active participation in sectional / departmental Safety Committees under the main Safety Committee.

4. Communication and Tracking System a) Formulate and implement a Comprehensive Communication Protocol clearly assigning duties and responsibilities of persons at various levels.

b) Establish Effective Communication System consisting of : Wireless Communication & Mobile / Landline Phones

- within the mine with face supervisors & attendance rooms and - at offices and residences of Managers & other key officials.

c) Strengthen communication system within DGMS offices and mine sites, besides other concerned agencies.

5. Constant Vigil on Dangers from Water Sources a) Fast and Accurate Mine Surveying and Platting Instruments along with associated Software. b) Use of latest Technology like GPS, GPR, Micro-Seismic Systems

to monitor the Workings, Barriers, Water Bodies and other associated Alarm System. c) Dump Slope Design and Monitoring using Latest Gadgets like Target less Theodolite, Infrared Sensors and Monitoring Instruments.

d) Design Embankments against rivers and jore to guard against Inundation keeping in view the engineering parameters. - Show construction details in the relevant plans. e) Warning Mechanism about impending heavy rains for taking necessary preventive actions. f) Also coordination with concerned agencies/departments about opening of dams in the rivers on the upstream side.

6. Safety Management System (SMS): [Strategies for Implementation and Path Forward]

a) Employ a sound Risk Analysis Process, - Conduct Risk Assessment, and - Develop a Safety Management Plan to address the significant hazards identified by the analysis/ assessment.

b) Adopt the process of Safety Management System and - Commit for proper formulation and implementation in totality.

c) Allocate necessary Resources for implementation of the control measures.

d) Organize necessary Training of all employees with the help of experts, both national and international, - for Optimal Adoption of the Safety Management System.

7. Accident Reduction Program: a) Identification of Fatal Risk Areas and Corrective Measures:

b) Detection of Fire and Spontaneous Heating through continuous monitoring and analysis of data and information;

c) Introduction of safe methods and system in adverse geo-mining

conditions.

d) Reduction of Accidents during Transportation.

e) Introduction of latest technology for anti collision and personal emergency devices to track the men and machinery in mines.

f) Elimination of Risk of Silicosis and Pneumoconiosis through use of effective dust control measures.

g) Regular Medical Surveillance on identified group of persons.

8. R&D and Innovation:

Reversal of Dumpers & Tippers:

- Several accidents have occurred in opencast mines while reversing of equipment especially in dumpers / tippers.

- The manufactures provide only audio visual alarm and rear view mirrors in the equipment, but the driver/ operator does not have a clear view of the rear side of the equipment.

- Operator takes the assistance of a spotter while reversing, who is exposed to danger of being crushed by equipment.

- The audio visual alarm warning at times may not provide sufficient time for the spotter and others to escape from the site and incidents/ accidents takes place.

Provision of Rear Vision System in Equipments

The system provides: a) A monitor installed inside the cabin and b) An automatic switch on the reverse gear which actuates ultra low light camera installed at rear of the vehicle.

The Safety is improved: • Rear view camera provides clear pictures of objects behind . • Assists rear view during reversing and turnings.

[Courtesy : Ambuja Cement]

Body Guard proximity detection and warning system

Features:

- Range from 1m to over 100m.- Operates in poor visibility

environments (such as smoke,

dust, dirt, darkness)- No constant cleaning or

maintenance.- Does not distract driver from

normal vehicle operation.- No infrastructure required (such

as GPS satellites)- The distance and types of

objects detected are individually

programmable

Orbit Communication Systems Pty Ltd., NSW, AustraliaAvailable on Google site

Dumping Alarms in Tippers & Tip Trailers

These dumping alarms acts a warning alarm to alert the driver about the bucket’s tipping condition.

[Courtesy : Ambuja Cement]

9. Some Important Safety Features for HEMM:a) Dumpers:

- Mechanical steering locking to prevent untoward movement of steering wheel and tyre while work persons working below the cabin while engine is running.

- Blind spot mirror apart from rear view mirror to enable operator to have clear visibility of blind spot in and around dumpers.

- Mechanical type Anti collision device to avoid head to tail collision on haul road such as tail gate, bumper extension or any other strong device.

b) Excavators: - All functions cut off switch,- Swing Motor Brake- Vent valve on top of hydraulic tank should be able to be

removed without any tool- A baffle plate between cold zone and hot zone.- Provision for Limiting of hydraulic cylinders – Stoppers.

c) Dozers:- Roll over protection - Turbo charger guard- Fire resistant hydraulic hoses and wiring near hot zone.

d) Common:- Fire resistant hydraulic hoses in place or ordinary hoses to decrease the chance of fire. All the sleeves and conducts where cable /wire are passed shall be fire resistant.- Seat belt for operators.- The approved type of fire suppression system.

AlsoThe stability of HEMM shall be carried out at least once in year and after every major over haul by an independent agency. 

10. Separate road for Light Motor Vehicles

A considerable number of fatal accidents occurred in the mine premises of Mechanized Open Cast Mines when Dumpers of high capacity rare over Light Motor Vehicles on the haul roads.

These accidents could have been averted if the Light Motor Vehicles would not have been allowed to ply on the haul roads and a separate road for Light Motor vehicles would have been provided and maintained in the mine premises. Therefore, in the interest of the safety of the persons employed in mines, a separate road in the mine premises for the light Motor Vehicles-used for inspection and transportation should be provided and maintained. This road should not cross the Haul Road at any place in the Mine premises.  

11. General:a) Facilities for monitoring the environmental parameters b) Arrangements for transport of men where long or arduous travel is involved, c) Structured Training in Safety Management of all front-line supervisory officials, for at least two weeks, once in every five years. d) Implementation of recommendations of DGMS (Tech) Circular No.18 of 1975 (Protection of workers against Noise & Vibration in Working Environment.)e) Install properly manned check gate(s) at the entrance(s) to check entry of unauthorized vehicles in mine premises, f) All persons engaged at any work within the mine premises to be provided relevant Training and other job-related briefings h) Drivers of vehicles to be explained the salient provisions of

“Traffic Rules".

 The Time has now come for a Mining Contractor to share all the responsibilities of a Mine Owner and ensure compliance of all the recommendations Safety Conferences and the provisions made under different statutes.

The ‘Mine Owner’, as defined in the proposed amendments of the Mines Act, also includes a Contractor as Mine Owner. The Contractors, therefore, should now mentally prepare themselves for these increased responsibilities.  

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