24885821 Education Health and Safety GENERAL SAFETY TOPICS Docs12

Safety in Iron Ore Open cast

Mines

BY Sumit Sinha (Mesco Steel)

Analysis on Fatal Accidents

• About 70 fatal accidents occurred due to machinery every year.

• Out of above accidents 60% are due to dumpers, trucks, and water tanker.

ACCIDENT SCENARIO OF HYDERABAD REGION – II (METAL MINES)

Fatal Serious

2006 2007 2008 2006 2007 2008

All India 54 56 63 63 63 55

Hyderabad Region – II 2 2 1 11 9 9

Bellary Sub Region 2 2 1 11 9 9

Bellary Dist. 0 1 0 1 0 1

IRON ORE PRODUCTION (2008-09) – 30 MT

NO OF OPENCAST MINES IN BELLARY, SANDUR AND HOSPET SECTOR - 74

HEMM POPULATION

EXCAVATORS – 250

DUMPERS/TIPPERS – 3000

DRILLS – 150

SUPERVISION

MANAGER – 74

ASSISTANT MANAGER – 200

FOREMEN – 300

WORKERS – 10000

CAUSE OF ACCIDENT: While reversing dumper in an over crowded

bench deceased was hit & run over by the dumper at contractor working area On 09.01.2008 at RG.OC.3

1FATAL ACCIDENT ANALYSIS OF SCCL OC MINES- 2008

FATAL ACCIDENT TO SRI A. PRASAD ,MACHINE HELPER ( CONTACTOR’S WORKER) AT ABOUT 7.00 PM IN 2 ND SHIFT ON 09.01.2008 AT OB OFFLOADING AREA IN RG OCP-III , RG 2

AREA.

CAUSE OF ACCIDENT

While carrying 4” flexible PVC pipe in a small water body having maximum depth of 3.5 m in de –coaled 3 seam area in order to dewater accumulated water by siphon method deceased got drowned which resulted in death.

2FATAL ACCIDENT ANALYSIS OF OC MINES- 2008

FATAL ACCIDENT TO SRI SUNKERI BALAIAH,GENERALMAZDOOR, OCCURRED AT ABOUT 11.45 AM in I shift on 23.02.2008 at MedipallI OC, RG-1 AREA.

Fatal accident to Sri Kondu Venkateswar Rao, EP.OperatorOccurred on 20.07.2008 in II shift at about 10.40 p.m. atRG.OC-I, RG.3.

CAUSE OF ACCIDENT.On 20.07.2008 in II shift at about 10.40 p.m., Sri KonduVenkateswar Rao, EP Operator, deployed on conveyanceLorry, while unauthorizedly operating the dozer at block-IVOB dump yard with the help of actual dozer operator Stumbled, fell on the ground and run over by the dozer.


CAUSE OF ACCIDENTOn 05.10.2008 in 3rd shift, Sri P.Satyanarayana Reddy, site In-charge and Sri B.Samuel, site Supervisor of M/s.BGR &Co. were ran over at the dump yard by truck No.59 while Reversing and received fatal injuries.


FATAL ACCIDENT OCCURRED AT JVR OC, SATHUPALLI ON 05.10.08 AT ABOUT 3.20 am IN 3RD SHIFT

RAN OVER AT DUMP YARD BY TRUCK NO .59 WHILE REVERSING AND RECEIVED FATAL INJURIES TO TWO PERSONS.

Name : D.VenkateshwarraoDesignation : Elec.Charge HandDate : 17.10.08Shift : Ist shiftTime : 15.00hrsCause of Accident : At About 15.00hrs near site office, while Sri D.Venkareshwar rao

electrical charge hand disconnecting power to street light fittings from 440v overhead line, having separate conductors for lighting on the same support ,inadvertently his left hand came into contact with 440v live conductors received electric shock and fell down from the ladder approximately from a height of 5.9 mtrs .Subsequently he succumbed to the injuries at area hospital at about 16.00hrs.


While deceased was driving a contractor’s jeep along with crew Of operation and maintenance, he hit side berm of the road and the jeep toppled towards its right side which fell on him and he Succumbed to fatal injury on 28.04.2008 at PK.OC.2, Manuguru

(NON STASTICAL ACCIDENT.)FATAL ACCIDENT ANALYSIS OF OC MINES- 2008

FATAL ACCIDENT TO SRI R. SRINU, DRIVER OF M/S PLR OFF-LOADING CONTRACTOR AT PK OC,MNG ON 02.02.09 AT ABOUT 6.10a.m

CAUSE OF ACCIDENT: ON 02.02.09 IN 1SHIFT AT ABOUT 6.10AM SRI R. SRINU, DRIVER OF M/S PLR OFF-LOADING CONTRACTOR WHILE BRINGING EMPTY WATER TANKERFROM DUMP YARD ALONG HAUL ROAD , HE HIT THE DIVIDER AND THE TANKER GOT TOPPLED DOWN TO RIGHT SIDE INFLICTING HIM FATAL INJURIES.

1

FATAL ACCIDENT 2009

Name : P.GaneshDesignation : Trip counter (Contactor workmen)Date : 14.02.09Shift : I st shiftTime : 5.00 hrsCause of Accident : On 14.02.09 in Ist shift at about 5.00am in southeast side first OB

Bench of off loading area, Sri P.Ganesh (contractor workmen) working as trip counter was hit by the motor grader moving in reverse direction when he was crossing the haul road received serious injuries on his head .Immidietly he was shifted to area hospital ramakrishnapur, for medical aid where he was declared dead.

2

FATAL ACCIDENT 2009

FATAL ACCIDENT OCCURRED AT JKOC ON 15.02.2006 IN 3 RD SHIFT AT ABOUT 2.00AM AT COAL BENCH While he was dozing 2ND coal bench for compaction for dumper movement, suddenly coal fallen on canopy,canopy collapsed and causing fatal injuries

2FATAL ACCIDENT 2006

Cause of accident : While he was dozing 2ND coal bench for compaction for dumper movement, suddenly coal fallen on canopy,canopy collapsed and causing fatal injuries.

Dozing shall be done always perpendicular to the bench

Minimum 2m. Distance shall be maintained from toe of the bench to Dozer

FATAL ACCIDENT OCCURRED TO

SRI M. JANARDHAN, HELPER/GREASER,

ON 02-06-2006 AT 4.30 PM AT

OFF-LOADING AREA OF PLR&CO.,

C.O.C., MANUGURU


Cause of the Accident:

Probably while Shri M. Janardhan, helper was approaching the shovel from

the side of stone boulder measuring approx

3M x 2.5M x 2.3M, the shovel operator not knowing his presence might have hit the

stone boulder with bucket. As a result the stone boulder rolled over him from a height of about 1 m in the same level and crushed

his left part of the body. He was succumbed to injuries on the way to

hospital.

FATAL ACCIDENT OCCURRED TO

SRI SK. RAMZAN, CABLE MAN,

ON 10-06-2006 AT P.K.OC-II

AT 5th O.B.BENCH, EAST

SECTION,

MANUGURU


Cause of the Accident: As per the Eye witnesses,IR-1 Drill was being turned to right direction in the process of Marching, Sri S.K.Ramzan, Cableman tried to pull the cable going underneath the track and he himself was dragged underneath the track and received fatal injuries.

01.Name of the Employee : K. RAJA BABU

02.Designation : contract workmen

03.Name of the Mine : JVR OCP

04.Date of Accident : 02-10-2006 in I shift9.30 AM

05.Nature of Accident : Fatal

06.Cause of Accident :

While he was attempting to start the Dozer by short circuiting

the self motor and sitting on the crawler track, the Dozer moved and he

fell between the C-Bar and crawler track causing fatal injuries.

4

JVR OC - FATAL ACCIDENT

111

Dozers

Shovels

Volvo Tippers Volvo Tippers

Volvo Tippers

Accident spot

Air filling shed

Welding Plant

Tinkering Shed

Tipper repair shed

Car shed

7.8m

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

20 19 18 17 16

4 3 2 1

2 1 28 27 26 25 24 23 22 21

PLAN SHOWING THE PLACE OF ACCIDENT

Pooja Site

Bucket

C-Frame

Self motor

Ignition key

Accelerator pedal

Parking brake

Track

Accelerator lever

Gear lever

Locking lever

Driver seat

Name : CH.Bhaskar raoDesignation : Greaser helper( contactor workmen)Date : 01.04.07Shift : III rd shiftTime : 0.30 hrsCause of Accident : Sri Annaji rao and Sri Bhasker rao both helpers were on the dozer

no.D5G7 during the break time hours. While Sri Ch.Bhaskar rao was alighting from the dozer,,Sri Annaji rao had started the dozer un authorisedly. In the process Ch.Bhaskar rao fell down accidentally and his right leg was crushed underneath the right side track chain of the dozer,which resulted in serious injuries and later succumbed to injury on the way to hospital in hyderabad at about 8.00am on 2.4.07.


FATAL ACCIDENT TO SRI .Sri Md.Raffi, Volvo operator on 05-12-2007 at RG- OCP-2 due to over turn of another dumper on the cabin.Cause of accident:Sri Mohd.Raffi went to dump yard and positioned his BenzTruck by the left side of another truck driven by VenkataSwamy. Sri Venkataswamy lifted the body of truck forDumping by raising to a height of 1.5mts. Which eventually toppled on to the cabin of truck positioned by Sri Mohd Raffi.


Fatal accident to Sri Rapuri Ramakrishnaiah, EP.Operator in III shift on 21.10.2007 at PK.OC-II,ManuguruCause of accidentWhile marching dozer in reverse direction towardsLower coal bench, the dozer got toppled from a heightOf 2 mts. from the edge of upper coal bench.


Fatal accident to Davood Beig, General Mazdoor in IShift on 15.11.2007 at OCP-II, RG-III.Cause of accident:Sri Davood Beig who was rear cabin of the van jumpedFrom the doors provided at the rear of the vehicle in Panicky when the van started running unattended and Ran over by it.


Fatal accident to Sri T.S.R.Anjaneyulu, Overman, in IIShift on 18.11.2007 at JVR.OC, SattupalliCause of accident:Sri TSR.Anjaneyulu was hit and run over fatally whileHe was crossing the road from behind the movingGrader in reverse direction during the process of cleaningSpillage ground coal near surface bunker.


General observations on the causes of accidents

Indiscipline/casual approach

Misadventure/Negligence

Non compliance of Road worthiness/fitness

Deployment of Unauthorized persons

Movement persons in and around HEMM

Over speeding/Over loading

Bye passing safety features in HEMM

Non compliance's of SOPs/COPs

• Identification and placement of right men for right job at right place in right time.• No person is being allowed into the quarry with out VTC training ,IME and identity card issued by manager. • All the operators including Volvo truck and dumper operators were issued hand book of code of practice • All the idle/break down machinery operating keys are being kept at safe custody.• Road worthiness of vehicles of Contractor as well as SCCL is being done by an engineer• Separate haul roads for 100 T Dumpers and volvo trucks are being maintained.• Separate dump yard are earmarked for dumping OB by 100 T Dumpers and volvo trucks.

Action plan for improvement of safety

• Shut down procedure is being followed before under taking repair or adjustments of electrical installations.

• Safety belts, earth sticks and gloves are being used while working on overhead line.

• All the workmen including contractor workmen have been issued code of practices on different activities and being practiced the same.

• Slope stability- scientific study, implementation ,Continuous monitoring, stabilization methods

• All the maintenance crew after maintenance are being sent out of the quarry.

• Trip counter and dump man are being placed at authorized elevated place which is away from the vehicle movement area.

• Radium sticker jackets were issued and wearing by all persons working in the quarry after day light hours.

• Register of near misses is being maintained.• Safety suggestion box is kept at manway office.• Blasting card system is being followed by blasting crew• Risk management plan review , up-dation and monitoring• Effective illumination.• Automatic fire fighting

• Educating the contractor workmen by safety committee members during their visit.

• safety awareness lecture is being Conducted, designation wise in every week by Safety officer.

• Implemented Dress code for Safety committee members and activated the pit safety committee members to bring awareness among workmen .

• Surprise inspections of the vehicles were being done to ensure only authorised person are driving the vehicles.

• Surprise inspections by senior officers in back shifts.

Dumpers, trucks & Water Tanker

Drills, compressor, dozer

Haul road, etc;

DGMS circulars

DGMS(Tech.) / circular no. 09 dt. 2nd Dec. 2008:Number of incidences and accidents has taken place

due to:1. Head on collision of dumpers on haul road due

to poor clear view.2. Front and rear collision of dumpers on haul

road. 3. . In advertent movement of steering wheel

among with tyre while maintenance of dumper where engine is ‘ON’.

4. Dumper getting off haul road due to inadequate parapet wall / berm.

5. While dumper being reversed

Haul road safety

• Height and Width of Haul road• a. No road shall be of width less than three times

plus 5 m. width of largest vehicle playing on the road.

• b. All corners and bends shall be made in such a way that the operator of vehicle have clear view of distance of not less than three times the braking distance of largest HEMM working at 40 KMPH

continue

• c. where it is not possible to ensure visibility for a distance as mentioned in (b) there shall be provided two roads of width not less than 2 times plus 3 m of largest vehicle plying on the road with strong road divider at center with adequate lighting and reflector along divider

continue

• D. Where any road exist above level of surrounding area it shall be provided with strong parapet wall with following dimensions:

• I. Width at top not less than 1 m.• II width at bottom not less than 2.5 m.• III The height not less than the diameter of

largest vehicle plying on the road.

DumpersFollowing safety features shall be

provided

• (i) Mechanical steering lock to prevent untoward movement of steering wheel & tyre while work person working below the cabin while engine is running.

• (ii) Blind spot mirror apart from rear view mirror to enable operator to have clear visibility of blind spot in and around dumpers

continue

• (iii) 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.

• (iv) Fire resistant Hydraulic hose in place of ordinary hoses to decrease chance of fire.

• (v) Seat belt for operator

continue

• (vi) Maximum speed of vehicle shall be restricted to 30 kmph by blocking high gear or any other automatic means.

• (vii) Propeller shaft guard.

• (viii) Proximity working device.

Excavators

• Following safety features shall be provided

• (i) All function cut off switch.

• (ii) Swing motor brake.

• (iii) Fire resistant hydraulic hose to decrease the chance of fire.

• (iv) Turbo charger guard.

• (iv) seat belt

continue

• (vi) vent valve on top of hydraulic tank should be able to be removed without any tools.

• (vii) A baffle plate between cold zone and hot zone.

• (viii) Provision for limiting of hydraulic cylinder.- stoppers

Drills

Following safety features shall be provided.

1. Approved type of dust suppression or prevention system.

2. Each moving parts shall be guarded / fenced and also ensured it’s effectiveness all the time.

continue

• . Propel joy stick – spring loaded type to Return to neutral (dead man safety).

• . Disc brake and brake valve and it’s testing parameters.

• . Seat belt• . Fire resistant hydraulic hose and wiring

near hot zone. • . Turbo charge guard

General

Audio visual reversing alarm shall be provided. The pressure vessel receiver are subjected to

hydraulic testing and NDT testing shall be carried out by competent persons.

In case of any defect in in equipment such as brake, steering and safety device the equipment shall be immediately taken out of use and record shall be kept

continue

• 7. The code of practice of installation, maintenance of all equipment shall be prepared and implemented before putting equipment in use at the mine.

Work Shop

Layout of work shop shall be required as per DGMS Circular no. 8 of 2003.

Present scenerio -• 1. Lack of proper parking places for

HEMM leading to haphazard parking.• 2. Canteen, time office, site office, cycle

shed, scooter shed located near the workshop.

Additional steps to be taken

.1. Proper maintenance,repair, overhaul and erection of HEMM.

2. Separate paths for the movement of HEMM & light vehicles.

3. Canteen, time office, site office and stores, two wheeler sheds etc. shall be located where the movement of HEMM is least.

4. Proper parking area for HEMM

Dozers

• Roll over protection shall be provided over operator cabin.

Measures to prevent accidents

DGMS approved type audio visual reversing alarm

• As per DGMS (Approval) Circular no./4 of 2008 : Audio visual reversing alarm for reversing of surface transport machinery & Heavy Earth Moving Machinery will not be used in the mines unless the same has been approved by DGMS with effect from 1st Sept. 2008

Automatic Fire Protection System in HEMM

DGMS(TECH.)(S&T)/ circular no. 1/697 dt.14th Aug, 2008:

• All types of fire fighting & fire suppression system including automatic fire detection and suppression system used in HEMM , material and chemical to be used in fire fighting or suppression system in mines

Luminaries for Lighting in mines

DGMS(Tech.)/ circular no. 4 of Feb. 2009:

• It is proposed that all lighting system and components in mines both on surface and below ground should be of type and standard approved from DGMS

Use of surveyed off equipments

DGMS(Tech.)/ circular no. 01 of 2009

• It has been observed that surveyed off equipments being used in open cast mine also causing increase in number of accidents..

Use of chemical additives for dust suppression in coal mines

DGMS(Tech.)(S&T)/ circular no. 2 / 700 Dt. 14th Aug. 2008.

• From 1st Nov. 2008 as the date from which al type of chemical dust suppressant including the additives used therein to be used for suppression of dust in the mine shall be of such type, standard and make approved by DGMS.

Drills: dust suppression system

DGMS(Approval) circular no. 05 of Nov. 2008 :

• Following items shall not be used in mine from 31st Dec. 2008 unless the same has been approved by DGMS.

• Dust suppression system/ preventive device in drilling and boring equipment.

Haul Road

DGMS (Tech.)/ circular no 6 of 2008 :

• Separate road shall be made for light vehicles in all the mines where dumpers 35 T and above capacity are deployed.

SAFETY BANK

• CREDIT IS ZERO ACCIDENT.

• DEBIT IS ANY ACCIDENT.

• GOD IS CREDITING 86400 SECONDS PER DAY TO YOUR SAFETY BANK.

• A LAPSE IN ONE SECOND WILL RESULT IN AN ACCIDENT.

• BE ALERT EVERY SECOND TO MAKE YOUR MINE ACCIDENT FREE IN 2009.

PUSH – N – CLOUDOF ACCIDENTS FROM YOUR MINE

• PROCRASTINATION• UNTRAINED• SHORT CUT METHOD• HURRIEDNESS• NEGLIGENCE• CARELESSNESS• LAZINESS• OVER CONFIDENCE• UN ATTENTIVENESS• DRUNKENNESS

1. COMMITMENT (Whole Hearted commitment to the goal)

2. CONFIDENCE (One should have Confidence on his Knowledge and Skills)

3. CONTENT(Content is obtained by acquiring Knowledge)

4. CONCENTRATION(Concentration on the work taken up is must)

5. COMMAND(Command on the subject,skills,performance & practice)

6. CREATIVITY(Creativity is only the root of modern Civilization)

7. COMMUNICATION(Communication revolution is going on currently)

8. CONSISTENCY(Consistency in work schedules and time management)

9. COOPERATION (Teamwork with superiors, colleagues & subordinates)

10. COORDINATION (Relationship with different jobs from different spheres

with different people)

10 C’s FOR ZERO ACCIDENT

BEHAVIOUR BASED SAFETY

Holnagel, 1993 study – 90% of work place accidents caused due to unsafe behavior of persons.

Workers stress and risk taking behavior.

Analysis of accidents on technical error approach without considering human error approach.

HUMAN BEHAVIOR AND STRESSStress is a state of affair involving demand on

physical or mental energy.Contributing factors.1) Environmental 2) Occupational3) Social4) Personal5) Biological6) Psychological

SYMPTOMS OF STRESS

1) PHYSICAL - Headache, B.P. raise, Heart problem, Bowel syndrome, weight loss, depletion of immune system

2) PSYCHOLOGICAL – Anxiety, anger, frustration, depression, memory loss, lack of motivation, lack of concentration, accident proneness.

CHARACTERSTICKS CONTRIBUTING TO ACCIDENTS

1) INDIVIDUAL – Experience, knowledge, skills, attitude towards safety.

2) JOB – Work task, work environment, job stress

3) MINE- Safety culture, social support, safety management systems.

IMPROVE YOUR SKILLS• 1. Seeing (Catch sight of, become aware of things around)

• 2. Watching (Look at attentively, keeps eyes open, pay attention)

• 3. Observation (Action of closely observing someone or something to notice important details)

• 4. Inspection (Officially looking closely to check on standards, scrutinizing,

surveying and investigation) • 5. Examination (Detailed inspection to analyze, apprise, assess the

subject)

• 6. Checking (Examining for accuracy, quality, conditions, standards, shortcomings, progress and compliance)

• 7. Testing (A procedure intended to establish the quality, performance or reliability, procedures include analysis, appraisal, assessment, auditing, checking, evaluation, examination, experimentation, inspection, interrogation, investigation, and probing)

TIPS TO REDUCE ACCIDENTS

• DAILY SAFETY PLEDGE.• SAFETY SUGGESTIONS FROM EVERY ONE.• PUBLIC ADDRESS SYSTEM AND SAFETY TALK.• SAFETY AWARD AND REWARD SYSTEM.• SAFETY OBSERVATION TOUR.• SAFETY ALERT MEETING.• NEAR MIS INCIDENTS REGISTER.• FAIL SAFE SYSTEM.• STRENGTHENING MINE SAFETY DEPARTMENT.• BRAIN STORMING SESSIONS.• YOGA AND MEDITATION.• STANDARD OPERATING PROCEDURE (SOP) AND CODE

OF SAFE PRACTICES (COSP).

Plans to be maintained

• Emergency plan• Risk Management Plan• Fire fighting Plan• Mine Illumination plan• Monsoon preparation plan• Partition plan for developed galleries• HEMM deployment plan• Slope stability and dump management plan• Environment management plan• Electrical power lay out

TIPS TO REDUCE STRESS TO WORKERS

• SAFETY POLICY• SAFETY MANAGEMENT SYSTEM• SAFETY CULTURE• SAFETY PRACTICES• SAFETY EFFICAY AND ATTITUDE• SAFETY BEHAVIOR• SAFETY CLIMATE• SAFETY AWARENESS• SAFETY EDUCATION AND TRAINING• SAFE PRODUCTION

MATURITY

• CHRNOLOGICAL MATURITY

• PHYSICAL MATURITY

• INTELLECTUAL MATURITY

• EMOTIONAL MATURITY

• SOCIAL MATURITY

• SPIRITUAL MATURITY

Vote for safety

Thinking safety is wisePlanning safety is wiserDoing safe things is wisest

Let us pledge to do every thing

safely now onwards

24885821 Education Health and Safety GENERAL SAFETY TOPICS Docs12

Documents

fatal accidents

stastical accident

fatal injury

hrs cause of accident

metal mines fatal serious

shift ran

nd shift

rd shift