Mining Safety: Challenges and Opportunities

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Dinesh SrivastavaJayaswal Neco Industries

Ltd

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Sarve bhadrani pashyantu, ma kascit dukha bhaga bhavet

May all be happy, may all be free from disease

May all have well-being and none have misery of any kind.

[Brihadaaranyaka Upanishad 1.4.14]

ॐ सर्वे� भर्वेन्तु सखि�नः सर्वे� सन्तु निनःरा�मयाः� ।सर्वे� भद्रा�णि� पश्याःन्तु

म� कणि�द्दुः� �भ�ग्भर्वे�तु� ।ॐ शा�न्तिःन्तु शा�न्तिःन्तु शा�न्तिःन्तु ॥

•Earliest Pre-Harappan Mining History.•Modern Mining era of Coal extraction started in 1774.•Only seven minerals were mined in the beginning of 20th Century. •Political Independence provided real boost to the growth of mining.• 22 Minerals were mined in 1950 valued at Rs. 70 cr.

• 84 major, 23 minor & 3 atomic minerals are mined now.

• Rs 2.10 lakh Cr worth value of minerals produced in 2011-12

• Accounts for 2.6% of the country’s GDP

• Accounts for 68.22% fuel minerals, 11.94% metallic,11.85% non-metallic including minor minerals at a total value of mineral production

India’s share to world’s Mineral Prod

• 1st in Mica.

• 2nd in Chromite.

• 3rd in Coal & Lignite.

• 4th in Iron Ore.

• 6th in Bauxite.

• 8th in Manganese Ore.

• 10th in Al

• 11th in crude steel.

• 4th in mineral prod in world

INTRODUCTION•History of mining in India is marred with sporadic occurrence of accidents involving a large number of fatalities.•Despite rapid advancement in technology and management, accidents in mines due to fall of roof and sides, rope haulages, wheeled trackless transportation machinery, fire, explosion, inundation, etc have been occurring now and then.

-The condition of being protected from or unlikely to cause danger, risk, or injury: "they should leave for their own safety". -Denoting something designed to prevent injury or damage: "a safety barrier"; "a safety helmet".

What does safety mean ?

Accident ?

•Conventionally, any mishap in which one or more persons are killed or injured constitutes an accident. Accident may be defined as an unexpected event causing loss of life or bodily injury•The Mines Act does not define an accident. Section 23 is simply titled as Notice to be given of accidents, but makes no attempt to define an accident.

ACCIDENT

Individual

Environment

System & equipment

Three elements of causation of accident

A tablet found in Portugal describes what must be the first Support rules:•“The roof is to be supported by leaving pillars or the use of props. It is forbidden to damage the pillars or remove the prop.

•In 1510 Agricola advised on support and ventilation, the main concern being safety rather than profit

• Till about 1930 it was believed that physical conditions were the cause of most of the accidents.

• Therefore corrective action was taken which showed good results. There was substantial reduction in the number of accidents

• But In 1931 HW Heinrich propounded a theory that unsafe acts of people cause more accidents than unsafe conditions

• He analyzed a large number of accidents and concluded that 98% of accidents were caused by hazardous conditions or dangerous acts and these could be prevented.

• Only 2% of the accidents were caused by the act of nature or GOD and were unpreventable.

• Out of 98% of preventable accidents 88% were caused by unsafe acts of men and only 10% were due to unsafe physical or mechanical conditions

The unsafe acts of men and unsafe mechanical and physical conditions is demonstrated by game of Domino and is demonstrated by oblong pieces of wood called dominoes.These are placed in a row in a manner that the fall of the first causes the fall of the entire row. But if any of the middle dominoes are removed the series is interrupted.

Ance

stry

sch

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ent

Fall

of p

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Uns

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Acci

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Inju

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The Five Factors in accident sequence

Dominoes sequence

1 2 3 4 5

Injury is caused by the action of preceding factors

Dominoes sequence

Removal of the central factor makes the action of preceding factor in

effective

Dominoes sequence

Five factors in injury sequence:•Ancestry and social environment

(undesirable traits of characters inherited/acquired from social environment)•Fault of person

(undesirable traits lead to faults of person)•Unsafe act and/or physical or mechanical hazards

(fault of person is responsible for unsafe acts/ the existing hazard)•Accident

(unsafe acts/conditions lead to accident)•Injury

(accidents lead to injury)

Safety and minesMine safety connotes the condition of being safe from hazards like:

•Which cause or could cause bodily injury

This constitute mine accident•Which are injurious to health

This causes occupational hazards

-Accidents can be recognized easily and immediately While occupational hazards develop slowly till worker is aware and loses bodily function

International experience shows that more people are killed or are disabled by occupational dieses of mining than accident

YET THE ACCIDENTS IN MINES RECEIVE THE SPOT LIGHT OF CONCERN WHILE THE SILENT KILLER AND OTHER ACCIDENTS GO UNNOTICED

Nation wise road accidents in India are 390 per dayIn 2012 17 lives were lost/hour as against 15 live in 2010•1.42 lakh people died in 2011•1.34 lakh people died in 2010•1.26 lakh people died in 2009•1.20 lakh people died in 2008•1.14 lakh people died in 2007

Fatalities on Road

ACCIDENT IN MINES

The term accident has been derived from the Latin word ‘Accidere’ which means ‘fall of an object’. Any falling object which causes damage to the men and machine is categorized as accident.

The Mines Act says: Whenever there occurs in or about a mine an accident causing loss of life or serious bodily injury, or an explosion, spontaneous heating, outbreak of fire, inrush of water or gas, premature collapse of any part of the workings, over-winding of cages, etc a notice has to be given immediately in the prescribed form to the prescribed authorities.(Even if there is no loss of life or injury, they are deemed to be accidents.)

Types of accidents• Disaster: mine accidents

having high risk and potential to inflict heavy fatality simultaneously damaging mining conditions and occurrence of 10 or more fatalities.

• Major accidents: involving fatalities more than 3 but less than 10

• Fatal accidents': resulting in fatalities up to three persons

• Serious: an accident describing ‘seriously bodily injury” means any injury which involves or in all probability will involve permanent loss of any part of body or injury to sight or hearing or any physical incapacity or the fracture.

• Reportable: means any injury other than a serious bodily injury which involves or in all possibility will involve the enforced absence of the injured for more than 72 hours.

• Minor: means a minor injury resulting in absence for more than 24 Hrs.

Measurement of safety• Safety can not be quantified• Absence of accident is no safety• Accident statistics are the only

yard stick to judge safety• International practice to

express accident rates is in relation to exposure i.e.:

• Death/injury rate on the basis of• One million man hour worked • One lakh man shifts worked• One thousand person

employed

• In India the frequency rate is calculated on one lakh man shifts worked or 1000 persons employed

• To calculate frequency rate per mill of production is also sometimes adopted but it does not reflect the real trend

ACCIDENTS• Fatal accidents in Coal mines (in India) in

last 112 years (Since 1900) are 7933 no’s average coming to 181 per year

Fatalities in China in coal mines in• 2011 1973• 2012 1384Around 7000 deaths recorded a decade agoMay 12 2013 – 40 fatalities in two minesMay 11 2013 – 22 fatalities Mar 13 2013 – 21 fatalities Jan 30 2013 – 12 fatalities Nov 24 2012 – 17 fatalities Nov 12 2011 – 20 fatalities 20 trapped in a pit in Meghalaya since July

6

On an average 250 persons are killed in mine accidents every year. Out of these 180 are killed in coal and 70 are killed in metal mines.The number of persons receiving serious bodily injury is about 1100 per year. Out of these 800 are injured in coal and about 300 in metal mines.

Place of accident Fatal accident Persons killed Serious accident

Seriously injured

Under ground 84 (62%) 122 (69%) 463 (70%) 503 (71%)Open Cast 29 (21%) 30 (17%) 70 (11%) 75 (11%)Above ground 24 (17%) 24 (14%) 125 (19%) 130 (18%)Total 100 100 100 100

Place wise analysis of accidents in coal mines

Three production/safety era in Indian coal history are considered important:•Pre independence era

1900 to1950•Post dependence pre nationalization

1850 to 1970•Post nationalization era

1970 to till date

The relation ship between production and safety can be related in three eras•Production and no or little safety•Safety and little production•Safety and production go togethersharp decline in fatality rate over a period of 100 years: Drop in fatality rate from a peak of 1.29 per 1000 persons in 1911 to 1920 deployed to 0.22 in 2011-12 mainly because of:•Share of u/g production dropped from 86.32% in 1951 to 9.35% in 2011-12•Share of o/c production increased from 13.68% in 1951 to 90.61% in 2011-12•At the time of nationalization heavy influx of person took place

No of fatalities in Indian Coal mines AV/YR

1901 to 1950 (50 yrs) 9880 197.61951 to 1970 (20 yrs) 5550 277.51970 to 2012 (42 yrs) 7833 186.5Total 112 yrs 23263 207.7Since last two years fatal accidents are all time low 112 in 2011,116 in 2012.Total no of accidents across coal, metal and oil mines has decreased more than half from 1358 in 2005 to 591 In 2012. T/mines- 566(Coal), -2500(metal), oil-29

There are 566 coal mines out of this 360 are u/g and 130 o/c while rest 76 are mixed mines

Out of around 5 lakh of workers 20% are deployed in o/c producing 85% production while 80% worker deployed in u/g produce only 15% production

This means more persons are exposed to danger in u/g.

It is generally perceived that o/c mines are safer than u/g. But if we calculate accident rate on mill ton and per mill man shift basis we fine this perception may not be true.

Safety perception o/c vs u/g mines

For the period between 1989 to 1997 (CIL)Based on production (mill t) accident rate is 1.236, 0.144, and 0.102 respectively for u/g, o/c and surface accidents. For a fixed amount of production accidents in u/g are 8.5 times more frequent than o/c.

Based on million man shift accident rate is 0.687, 0.579 and 0.160 respectively for u/g, o/c and surface. For fixed mill man shifts accidents in u/g and o/c are comparable.For pooled data of all companies in CIL for the period for all types of accident combined the rate is 0.526 based on mill ton is comparable to 0.822 if based on per million man shift.On mill ton basis NEC, BCCL, ECL and CCL are more accident proneOn mill man shift basis BCCL, MCL and NEC are more accident prone

1995 1996 1997 1998 1999 2000

Fatal Accident in coal mines

A K A K A K A K A K A K

U/G 91 173 75 88 94 114 80 97 74 84 63 76

O/C 26 26 27 29 27 29 24 24 30 31 39 52

Serious Accident in O/C coal mines

U/G 549 595 478 514 440 477 346 380 408 446 434 466

O/C 69 71 71 75 79 85 72 73 77 85 104 111

Trend in accidents (Six Years)

A- Accidents, K- Killed

Year Av No of Accidents

Accident rate

Av no of fatalities

Fatality rates

1901-10 74 0.77 92 0.941911-20 138 0.94 176 1.291921-30 174 0.99 219 1.241931-40 172 0.98 228 1.331941-50 236 0.87 273 1.011951-60 222 0.61 295 0.821961-70 202 0.48 260 0.621971-80 187 0.46 264 0.551981-90 162 0.30 184 0.3491-2000 145 0.27 170 0.33

FATAL ACCIDENTS AND FATALITIES

Accident and death rates are per ‘000 persons deployed

Year No of fatal accidents

No Killed D.Rate/1000 persons

D.Rate/Mill te

1951 278 319 0.91 9.3

1961 222 268 0.65 4.81

1971 199 231 0.60 3.05

1981 165 184 0.36 1.45

1991 138 143 0.26 0.60

2000 117 144 0.31 0.43

2001 105 141 0.32 0.41

2002 81 97 0.23 0.27

2003 83 113 0.27 0.30

2004 87 96 0.24 0.26

2005 96 117 0.29 0.29

2006 79 138 0.36 0.34

2007 77 79 0.20 0.19

2008 87 100 0.25 0.24

Accident statistics 1951 to 2008 (58 years)

Causes of accidents

Fatal Accidents (%) Serious Accidents (%)

Accident Deaths Accidents Injuries

Roof Fall 43.6 41.9 12.5 14.9

Side Fall 14.0 11.1 7.7 7.7

OtherG/movement

0.8 1.4 0.2 0.8

Haulage 17.0 13.0 25.7 24.3

Conveyors 1.5 1.1 1.3 1.2

Transport m/c 1.2 1.0 1.0 1.0

Other m/c 2.3 1.7 2.2 2.2

Explosive 4.0 3.6 1.8 3.1

Gas /dust/ fire 1.7 3.5 0.1 0.1

Fall of person 6.1 4.6 22.5 20.9

Fall of object 1.7 1.3 15.7 14.6

Other causes 6.1 15.8 9.3 9.2

All causes 100 100 100 100

Cause wise analysis of accidents in u/g for 6 years

Cause of accident Fatal accidents (%) Serious accidents (%)

Accidents Deaths Accidents Injured

Fall of overhangs 5.2 9.4 1.1 1.0

Dumpers/trucks 54.9 53.4 27.6 29.6

HEMM 17.3 15.7 18.0 17.2

Fall of persons 3.5 3.1 27.5 26.0

Fall of object 3.5 3.7 11.0 10.6

Other causes 15.6 14.7 14.8 15.6

Total 100 100 100 100

Cause wise % of accidents in o/c for 6 years

Exp/Fire Inundation

Fall of roof/sides

Others All cause

1991-25 (25 yrs) 10 2 2 3 17

1926-47 (22 Yrs)

5 2 1 2 10

1948-73 (26 yrs) 5 5 2 0 12

1974-2K (27yrs) 5 5 2 0 12

2001-05 (05 yrs) 0 3 1 0 4

Cause wise period wise no of disaster

Inundation

Exp/Fire Inu Fall of roof/side

Others All cause

1991-25 (25 yrs) 0.40 0.08 0.08 0.12 0.18

1926-47 (22 Yrs) 0.23 0.90 0.05 0.90 0.45

1948-73 (26 yrs) 0.19 0.19 0.08 0.00 0.46

1974-2K (27 yrs) 5 5 2 0 12

2001-05 (05 yrs) 0 3 1 0 4

Cause wise wise no of disaster per year

ACCIDENT COST

TO EMPLOYER• Medical Treatment• Compensation• Pension• First Aid• Loss of Production

• Plant Damage.

TO EMPLOYEE• Decreased

Income• Financial Loss

attributable to decreased income.

• Loss of Earning Power

Direct Costs

TO EMPLOYEE• Personal Pain &

mental concern• Inability to enjoy

normal relations• Problem in family

life• Loss of morale• Economic loss to the

family• Loss of time of

fellow workmen

TO EMPLOYER• Loss of Employee’s

skill• Loss of production• Accident Enquiries

& Reports• Labour unrest• Damage to m/c • Loss of time• Spoiled job• Breaking in new

men

Indirect cost

After analyzing every thing question is what do we do to reduce accidents?

Fatal accident is worst form of accident as well occupational dieses so:We need to evolve a strategy at firsthand to provide condition for Minimum accident potential (MAP) in a mine.

And finally to map out to achieve Zero Accident Potential (ZAP).(This recommendation was made by Fourth conference of Mines safety held in Dec’1978)

Challenge Opportunity

• Challenges and opportunities are complementary and supplementary to each other

• Each follow the other• Are two sides of the same coin

Environment

Challenges and opportunities

Challenge/Opportunities

Since 88% accidents are due to act of men – it can be corrected by:(Correct men)EducationTraining Provide good living conditionsControl of physical/mechanical hazardsStrengthen VTCUse of protective wears*Follow safety rulesAvoid unsafe actkeep away from moving machine

“SAFETY IS MY RESPONDBILITY” nation wide campaign was launched on 4/5 July’2013 in the inaugural function of 11th safety conference in mine.Each mine worker to carry a card containing 10 important questions reminding employees to ask before the start of work in mine.If no he should take up with his senior supervisor

SAFETY IS MY RESPONSIBILITY

1. Have I been adequately trained for the work or am I with an adequately trained supervisor.2. Does a SOP exists for this work.3. Do I have required knowledge

about this work place.4. Are the suitable tools and equipment provided and are they in good condition.5. Do I have necessary PPE.

6. Do I have required authorization/permit permission for

the work.7. Can whether working condition,

work environment or poor lighting affect job safety.

8. Are there any danger created by my activities or am I in danger due to

others activities.9. Are work environment hazards to

health.10. In the event of emergency do I know the emergency plan.

To achieve ZAP it is important to ensure technological control of hazardous conditions which encompass four engineering aspect like:•Design•Construction•Operation •Maintenance

These are mutually interdependent•Good - design reduces the hazards•Construction and operation -minimize maintenance•Maintenance in turn -allows machines optimum quality of safe operation

ZERO ACCIDENT POTENTIAL

Correct conditionsBring down the hazards by all means to an acceptable level.•Improve ventilation/lighting•Make Equipment less noisy•Provide better amenities at site•Maintain safety devices operative •Maintain good house keeping•Avoid defective/damaged/faulty design of equipment•Maintain protective devices

In last two decades, coal mining has witnessed a phenomenal growth in production from 75mill Te in 1971-72 to 554 mill Te in 2011-12, 557.5 mill te in 2012-2013. Coal Vision 2025 estimates demand of coal for up to 2024-25 for the different sectors based on the forecast made by TERI considering the coal demand and the change in the GDP. The adopted approach indicates that the over all growth in coal demand Is expected to be 5.62% with 8% GDPand 5.04% with 7% GDP. Sector-wise coal demand as assessed with the above approach for the two scenarios are given

Future coal demand

Production PlanConsidering high growth in coal demand, either as per Coal Vision 2025, or as per the estimates of the Administrative Ministries of coal consuming sectors, there is a need to increase the availability of coal from the indigenous sources. With this in mind coal production programme in different “PlanPeriods” has been worked out. Coal demand (with8% growth of GDP), as per Coal Vision 2025 document, is expected to rise to 1267 million tonnes per annum by 2024-25.

• Deep u/g minesDeep mines (+450 to 500m depth)Bad roof conditionsGassy seamsVentilationEnvironmental monitoringWater logged areas

• Large o/c minesMore depth up to 500m with SR 1in 7to15High capacity equipment , 40 Cum shovels, 80 Cum D/Lines, large dia drills, 240 T dumpersHighly productive mines, 20/30/4 mill teHigh consumption of explosiveNo of blasts

• Existing legislative provisions do not match with the newer technology

• Standard or safe operating procedures are yet to be developed leading to safe operations

• Work persons are not educated, skilled or trained to adopt such new technology enhancing chances of more human error

Legislative provisions

• Gradual shift from prescriptive legislation of the present to a goal setting legislation with built in-mechanism for risk assessment and formulation of safety, health and environment management plan

• Develop more flexible regulation with simple and easy process for amendment to keep the regulation updated and pace with changing need of industry

Various levels of participation• Workmen’s inspectors• Mine level safety committees –

Monthly meetings• Area level Bipartite /Tripartite

safety committees – Bi-annual meetings

• Subsidiary Company level Tripartite safety commitees - Biannually

• Coal India safety Board meeting – Biannually

• Standing Committees on Safety in Coal Industry – Biannual meetings Chaired by MOC

Shortage of manpowerNo study available as yet?CIL has 371546 employees on Mar’13Supervisors -37855Workers -334359Executives -156431 Total(Mar’2010) -387645CIL plans to recruit 3000 exe per yearShortage of executive is 40007 to 8K employees leave every year700 to 800 exe leave CIL every year There was recruitment holiday in CIL for 12 yearsTotal m/p in mining industry- 1.00 mill

• Most of the VRS/leaving co comes from u/g mine all category, skilled ,semi skilled and un skilled .

• The plan to produce 150 MTPY from u/g may fail as hardly any person shall be available for u/g

• MPT require high skill and if nothing is done for skill development or training to enhance skill there is answer from where u/g coal would come.

Environmental damage

Land degradationDe-forestationPolluted air/waterNoise pollutionRe-afforestation

we cut a (?) old tree and plant a sapling

Land scapeObstruction to sight

CommunityRehabilitation/resettlement

Private blocks and out sourcing

Coal blocks & contractors workers. Mar’2011 out 194 blocks 86 were scheduled to produce coal.Only 28 blocks were in production. Produced 36.80 MT coal in 2012-13 against a target of 42 MT.Was 7% of India’s production of 557.5 MT.Since FY 2007 (17.61 MT) growth is (+) 200%. These blocks have important role in bridging gap in demand & supply.

These mines are extensively worked by out sourcing.so actual accidents statistics may not be available of such mines. No of contractors workers are not available to make scientific studies of any kind.With such mines real challenge is if are we not entering in the same old golden era of pre-nationalisation.Will we lose the objectives of nationalization ?

Thank you all

For having heard me so patiently

Predominant cause of accident U/G mines:•Fall of roof -44.60%•Fall of side -14.14%•Rope haulage -16.91%•Other transport machinery-2.62%•Machinery other than transport machinery -2.48%•Explosive -4.37%•Fall of persons -5.40%•Others -