Transcript Document

WELCOME
TO ALL
ATTENDEES IN THE HALL
FOR AN ADDRESS ON
Mining Safety:
Challenges and Opportunities
Dinesh Srivastava
Jayaswal Neco Industries Ltd
Jh x.ks’kk; ue%
ॐ सर्वे भर्वन्तु सखु िनः
सर्वे सन्तु ननरामयाः ।
सर्वे भद्राखि पश्यन्तु
मा कश्श्िद्ुःिभाग्भर्वेत ् ।
ॐ शाश्न्तः शाश्न्तः शाश्न्तः
॥
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]
• 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
country’s GDP
2.6%
of
the
• 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.
What does safety mean ?
-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".
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.
Three elements of causation of accident
Environment
ACCIDENT
System &
equipment
Individual
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.
1
2
3
Injury
Accident
Unsafe act/condition
Fall of person
Ancestry school
environment
Dominoes sequence
4
5
The Five Factors in accident sequence
Dominoes sequence
Injury is caused by the action of
preceding factors
Dominoes sequence
Removal of the central factor makes
the action of preceding factor in
effective
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 mines
Mine 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
Fatalities on Road
Nation wise road accidents in
India are 390 per day
In 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
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
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
1384
Around 7000 deaths recorded a decade ago
May 12 2013 – 40 fatalities in two mines
May 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 wise analysis of accidents in coal 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%)
100
100
100
100
Total
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 together
sharp 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
197.6
1951 to 1970 (20 yrs)
5550
277.5
1970 to 2012 (42 yrs)
7833
186.5
Total
112 yrs
23263 207.7
Since 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
exposed to danger in u/g.
are
Safety perception o/c vs u/g mines
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.
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 prone
On mill man shift basis BCCL, MCL and
NEC are more accident prone
Trend in accidents (Six Years)
1995
1996
1997
1998
1999
2000
Fatal Accident in coal mines
U/G
O/C
A
K
A
K
A
K
A
K
A
K
A
K
91
173
75
88
94
114
80
97
74
84
63
76
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
A- Accidents, K- Killed
FATAL ACCIDENTS AND FATALITIES
Year
Av No of Accident Av no of
Fatality
Accidents
rate
fatalities
rates
1901-10
74
0.77
92
0.94
1911-20
138
0.94
176
1.29
1921-30
174
0.99
219
1.24
1931-40
172
0.98
228
1.33
1941-50
236
0.87
273
1.01
1951-60
222
0.61
295
0.82
1961-70
202
0.48
260
0.62
1971-80
187
0.46
264
0.55
1981-90
162
0.30
184
0.34
91-2000
145
0.27
170
0.33
Accident and death rates are per ‘000 persons deployed
Accident statistics 1951 to 2008 (58 years)
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
Cause wise analysis of accidents in u/g for 6 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
Other
G/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 % of accidents in o/c 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 period wise no of disaster
Exp/Fire Inund
ation
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 wise no of disaster per year
Exp/Fire Inu
Fall of
Others
All
roof/side
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
Inundation
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
ACCIDENT COST
Direct Costs
TO EMPLOYER
TO EMPLOYEE
• Medical Treatment • Decreased
Income
• Compensation
• Financial Loss
• Pension
attributable to
• First Aid
decreased
• Loss of Production income.
• Plant Damage.
• Loss of Earning
Power
Indirect cost
•
•
•
•
•
•
•
•
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
•
•
•
•
•
•
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
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 first
hand 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)
Challenges and opportunities
Challenge
Environment
Opportunity
• Challenges and opportunities are complementary
and supplementary to each other
• Each follow the other
• Are two sides of the same coin
Challenge/Opportunities
Since 88% accidents are due to act of
men – it can be corrected by:
(Correct men)
Education
Training
Provide good living conditions
Control of physical/mechanical hazards
Strengthen VTC
Use of protective wears*
Follow safety rules
Avoid unsafe act
keep away from moving machine
SAFETY IS MY RESPONSIBILITY
“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
1.
2.
3.
4.
5.
Have I been adequately trained
for the work or am I with an
adequately trained supervisor.
Does a SOP exists for this work.
Do I have required knowledge
about this work place.
Are the suitable tools and
equipment provided and are
they in good condition.
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.
ZERO ACCIDENT POTENTIAL
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
Correct conditions
Bring 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
Future coal demand
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
Production Plan
Considering
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 mines
Deep mines (+450 to 500m depth)
Bad roof conditions
Gassy seams
Ventilation
Environmental monitoring
Water logged areas
• Large o/c mines
More depth up to 500m with SR 1in 7to15
High capacity equipment ,
40 Cum shovels, 80 Cum D/Lines,
large dia drills,
240 T dumpers
Highly productive mines, 20/30/4 mill te
High consumption of explosive
No of blasts
Legislative provisions
• 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
• 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 manpower
No study available as yet?
CIL has 371546 employees on Mar’13
Supervisors
-37855
Workers
-334359
Executives
-156431
Total(Mar’2010) -387645
CIL plans to recruit 3000 exe per year
Shortage of executive is 4000
7 to 8K employees leave every year
700 to 800 exe leave CIL every year
There was recruitment holiday in CIL
for 12 years
Total 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 degradation
De-forestation
Polluted air/water
Noise pollution
Re-afforestation
we cut a (?) old tree and plant a
sapling
Land scape
Obstruction to sight
Community
Rehabilitation/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
•
•
•
•
•