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
 NO OF OPENCAST MINES IN BELLARY,
SANDUR AND HOSPET SECTOR - 74
IRON ORE PRODUCTION (2008-09) – 30 MT
HEMM POPULATION
EXCAVATORS – 250
DUMPERS/TIPPERS – 3000
DRILLS – 150
SUPERVISION
MANAGER – 74
ASSISTANT MANAGER – 200
FOREMEN – 300
WORKERS – 10000
 1
FATAL 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 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
 2
FATAL ACCIDENT ANALYSIS OF OC MINES- 2008

FATAL ACCIDENT TO SRI SUNKERI BALAIAH,GENERAL

MAZDOOR, OCCURRED AT ABOUT 11.45 AM in I shift
on 23.02.2008 at MedipallI OC, RG-1 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.
 3
FATAL ACCIDENT ANALYSIS OF OC MINES- 2008
Fatal accident to Sri Kondu Venkateswar Rao, EP.Operator
Occurred on 20.07.2008 in II shift at about 10.40 p.m. at
RG.OC-I, RG.3.
CAUSE OF ACCIDENT.
On 20.07.2008 in II shift at about 10.40 p.m., Sri Kondu
Venkateswar Rao, EP Operator, deployed on conveyance
Lorry, while unauthorizedly operating the dozer at block-IV
OB dump yard with the help of actual dozer operator
Stumbled, fell on the ground and run over by the dozer.
 4
FATAL ACCIDENT ANALYSIS OF OC MINES- 2008
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.

CAUSE OF ACCIDENT
On 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.
 5
FATAL ACCIDENT ANALYSIS OF OC MINES- 2008

Name : D.Venkateshwarrao
Designation : Elec.Charge Hand
Date : 17.10.08
Shift : Ist shift
Time : 15.00hrs
Cause 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.
 (NON STASTICAL ACCIDENT.)
FATAL ACCIDENT ANALYSIS OF OC MINES- 2008

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
 1
FATAL ACCIDENT 2009

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 TANKER
FROM DUMP YARD ALONG HAUL ROAD , HE HIT THE
DIVIDER AND THE TANKER GOT TOPPLED DOWN TO RIGHT
SIDE INFLICTING HIM FATAL INJURIES.
 2
FATAL ACCIDENT 2009
Name : P.Ganesh
Designation : Trip counter (Contactor workmen)
Date : 14.02.09
Shift : I st shift
Time : 5.00 hrs
Cause 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 2006
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

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
 2
FATAL ACCIDENT 2006
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.
 3
FATAL ACCIDENT 2006
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.
 4
JVR OC - FATAL ACCIDENT

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.
 PLAN SHOWING THE PLACE OF ACCIDENT

111 Volvo Tippers

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

Car Air filling

shed shed
Pooja Site
Tipper Accident spot Welding
repair Plant
shed 7.8m
Dozers Tinkering
4 3 2 1 Shed

2 1
28 27 26 25 24 23 22 21 Shovels
20 19 18 17 16
Volvo Tippers Volvo Tippers
 Bucket

C-Frame

Self motor

Accelerator lever
Ignition key
Gear lever Accelerator pedal

Parking brake

Locking lever
Driver
seat
Track
 1
FATAL ACCIDENT 2007

Name : CH.Bhaskar rao

Designation : Greaser helper( contactor workmen)
Date : 01.04.07
Shift : III rd shift
Time : 0.30 hrs
Cause 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.
 2
FATAL ACCIDENT 2007
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 Benz
Truck by the left side of another truck driven by Venkata
Swamy. Sri Venkataswamy lifted the body of truck for
Dumping by raising to a height of 1.5mts. Which eventually toppled on to the
cabin of truck positioned by Sri Mohd Raffi.
 3
FATAL ACCIDENT 2007
Fatal accident to Sri Rapuri Ramakrishnaiah,
EP.Operator in III shift on 21.10.2007 at PK.OC-II,
Manuguru
Cause of accident
While marching dozer in reverse direction towards
Lower coal bench, the dozer got toppled from a height
Of 2 mts. from the edge of upper coal bench.
 4
FATAL ACCIDENT 2007
Fatal accident to Davood Beig, General Mazdoor in I
Shift on 15.11.2007 at OCP-II, RG-III.
Cause of accident:
Sri Davood Beig who was rear cabin of the van jumped
From the doors provided at the rear of the vehicle in
Panicky when the van started running unattended and
Ran over by it.
 5
FATAL ACCIDENT 2007
Fatal accident to Sri T.S.R.Anjaneyulu, Overman, in II
Shift on 18.11.2007 at JVR.OC, Sattupalli
Cause of accident:
Sri TSR.Anjaneyulu was hit and run over fatally while
He was crossing the road from behind the moving
Grader in reverse direction during the process of cleaning
Spillage 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
Action plan for improvement of safety

• 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.
• 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.
 DGMS circulars

Dumpers, trucks & Water Tanker

Drills, compressor, dozer
Haul road, etc;
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.
 Dumpers
Following 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 – CLOUD
OF ACCIDENTS FROM YOUR MINE

• PROCRASTINATION
• UNTRAINED
• SHORT CUT METHOD
• HURRIEDNESS
• NEGLIGENCE
• CARELESSNESS
• LAZINESS
• OVER CONFIDENCE
• UN ATTENTIVENESS
• DRUNKENNESS
 10 C’s FOR ZERO ACCIDENT

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)
 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 STRESS
Stress is a state of affair involving demand on
physical or mental energy.
Contributing factors.
1) Environmental
2) Occupational
3) Social
4) Personal
5) Biological
6) 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 wise

Planning safety is wiser
Doing safe things is wisest
Let us pledge to do every thing
safely now onwards