Post on 29-Oct-2020
Jharia Division
Welcome to Chairpersons & Participants
Safety Symposium & Exposition 2015
Proactive Approaches towards Safety at Workplace &
Beyond
1
Jharia Division
Mr. Sanjay Kumar Singh General Manager, Jharia Division, Tata Steel Ltd
Proactive approach towards Safety in Coal Mines
2
Jharia Division
Jamsetji Tata
(1839 – 1904)
Founder “In a free enterprise, the community is not just another stake
holder in the business but in fact the very purpose of its
existence.”
66% of the equity of Tata Sons, the promoter holding company,
is held by philanthropic Trusts.
Corporate Social Responsibility - Essential component of our business practices.
The triple bottom line (people, planet and profit) - A legacy.
Concern for the Community and Environment - Our heritage.
Tata Group - A Heritage of Sustainability Thoughts and Practices
3
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Western
Europe
SE Asia
Scandinavia
China
CEE
Western
Africa
Ivory Coast
(iron ore) Mozambique
(coal)
Oman
(limestone)
Orissa
Steel making operations
Distribution and Commercial Centres
including downstream assets
Mining assets &
projects
North America
Latin America
NML, Canada
(iron ore)
India
Turkey
South Africa
Tata Steel Group
Tata Steel India
NatSteel Tata Steel Thailand
Tata Steel Europe
Product Segments
Present in developed and developing markets across a wide range of segments
A Global Steel Company Ranked 11th (year 2014) in World in
global steel production.
Revenue (FY15): TATA Steel Group:
~Rs.1,40,000 cr. ($ 25bn.)
6
Jharia Division
Purchased
coal
Coke
ovens
Sinter+Pell
et plants
Blast
Furnaces
Steelmaking
shop LD 1
Steelmaking
shops LD 2,3
Billet
casters
Slab/ TS
casters
Long
products
Flat
products
Tata Steel Operations
Raw
Material Coke Sinter Iron Steel Making
Marketing and
Sales
Finance
&
Accounts
Human
Resource Engg.
Project
Corp.
Functions Shared
Services
Own
Coal
Own
Iron
Ore
Customers
7
Manganese,
Dolomite
7
Jharia Division 8
Tata Steel India- Coal Mining Operation
• 6.00 MTPA Raw Coal Production • Open Cast Mining Operations • 100 T Dumper and 16 m3 Hydraulic Shovel • Clean Coal is despatch to Jamshedpur
after washing of Raw Coal.
• 1.6 MTPA Raw Coal Production • Underground Mining Operations • 3m3 LHD/1 M3 LHD/1 m3 SDL • Mine entry through Vertical shaft • Working depth 500 m. • Hydraulic Stowing with sand. • Clean Coal is despatch to Jamshedpur
after washing of Raw Coal.
8
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
History of mining disasters in India since 1910.
0
5
10
15
20
25
0
200
400
600
800
1000
1200
1400
Firedam
p a
nd
Coal D
ust…
Inu
nda
tions
Min
e F
ire
s
Rock B
urs
tsand B
um
ps
Co
llapse
of
Pill
ars
Sid
e F
all
Roof
Fa
ll
Air B
last
Bla
sting
No. of person Killed
No. of disaster
11
No
. o
f p
ers
on
No
. o
f d
isaste
r
7 disasters killing 144 persons from 2000 to 2014: • 3 inundations • 2 fire & explosion • 2 ground failure
Jharia Division 12
Safety Statistics- Indian Mining Industry
0
0.2
0.4
0.6
0.8
1
1.2
1.41
90
1-1
0
19
11
-20
19
21
-30
19
31
-40
19
41
-50
19
51
-60
19
61
-70
19
71
-80
19
81
-90
19
91
-00
20
01
-10
20
11
-14
De
ath
Rat
e
Decade
Coal mines
Non-coal mines
TREND IN DEATH RATE
PER 1000 PERSONS EMPLOYED
12
Jharia Division 13
Production & Manpower trend- Coal Mining
0
100
200
300
400
500
600
1950 1960 1970 1980 1990 2000 2010
Ou
tpu
t in
'00
0 t
on
s
Year
Trend in production of coal- Placewise
U/G Opencast
13
Jharia Division 14
0
50
100
150
200
250
300
3501
95
1
19
71
19
91
19
93
19
95
19
97
19
99
20
01
20
03
20
05
20
07
20
09
20
11
Man
po
we
r in
‘00
0
Year
U/G O/C
Manpower trend in coal mines- Opencast & Under ground
Production & Manpower trend- Coal Mining
14
Jharia Division 15
Current Safety Scenario
• Coal mining
contributes around
70% of all mining
accidents.
• Main causes are fall of
roof & sides, rope
haulages, fall of
person, gas & dust and
explosives in
underground operation.
• Roof fall and side fall
accidents accounted
for about 12% of all
fatal accidents during
the year 2014.
• In opencast operation,
mostly accidents are
caused due to HEMM
operation (39.29%).
15
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division 18
Safety Excellence Journey at Jharia Division
2
4 3
0 1
2
0
2
4
6
8
10
FY05 FY06 FY07 FY08 FY09 FY10
No
of
Acc
ide
nts
Fatal Accident at Jharia Division and Raw Material Division of TATA Steel
Raw Materials Division
JhariaSafety Excellence Journey Launched
Jharia Division 19
Cause wise analysis of Fatal and Serious Accidents
Data analysis of Accidents in Jharia (since 1999-FY10)
15
2 2 1 1 1
68 77
86 91 95 100
0
25
50
75
100
0
11
22
Fa
ll o
f R
oo
f &
Sid
e
Fa
ll o
f p
ers
on
s
Ro
pe
hau
lag
e /
To
b m
ov
em
en
t
Hit
by
Ob
jects
Inru
sh
of
Wa
ter
Oth
ers
Cu
m %
No
s.
Cause of accident
Conclusion: Fall of Roof & Side accounts for more than 68 % of total accidents.
Employee type wise
9 3 3
60 80 100
0
25
50
75
100
0
Face
em
plo
ye
es
Su
pp
ort
em
plo
ye
es
Su
perv
iso
rs
Cu
m %
No
s.o
f A
cc
ide
nts
9 3 3
60 80 100
0
25
50
75
100
0
Wit
hin
10 M
tr
10-5
0M
trs
Mo
reth
an
50
Mtr
s
Cu
m %
No
s o
f A
cc
ide
nts
.
Working Place wise
Conclusion: Employees within 10 Meters of the working face are more vulnerable to accidents.
Analysis of Accidents due to Roof & Side Falls
19
Jharia Division 20
Cause & Effect for “Fall of Roof & Sides within 10 Meters”.
Jharia Division 21
6
2 1
67
89 100
0
25
50
75
100
0
3
6
9
Improper RoofSupport
Inadequate SideSupport
Unsupported Roof
Cu
mu
lati
ve %
No
of
Acc
ide
nts
Causes for Accidents
Nos
Cumm %
Cause & Effect for “Fall of Roof & Sides within 10 Meters”.
89% Vital Few was considered for Action
Data Analysis of Main Causes for accidents – roof & side fall within 10 meters from the working front
21
Jharia Division 22
Analysis of causes
Sl
N
o
Caus
e
Sub
Causes
Why Why Why Why How
1. Roof
fall
Improper
Roof
Support
a. Roof support
design was
based on
Rock mass
Rating (RMR)
at one place
for the seam
b. The Roof Bolt
system
design fails at
places
against
expectation.
a. As per
practice the
SSR is
determined
once for the
seam as per
statute
b. Binder
between coal
and roof bolt
fails to take
support
c. The length of
roof bolt
does not
holds at some
places
a. At shallow depths
the seam
properties does
not changes much
b. The cement
capsule take 30
minutes for
setting
c. Cement capsules
fails to disperse
properly and can
stuck on one side
d. One length of roof
bolt is used at all
places.
a. Statute does not
require to
determine RMR
for the each
districts in a
seam.
b. The chemistry
does not allows
to set it faster.
c. No provision for
proper churning
of cement
capsule
d. No study of
effect of length of
roof bolt.
a. Joint R&D
with CIMFR
to
determine
Geophysical
properties
for each
working
district.
b. Use of resin
capsule.
c. Change in
design of
roof bolt to
facilitate
churning
d. 1.94 mts
roof bolts to
be used
2. Side
fall
Inadequat
e Side
Support
a. No side
bolting
provision in
SSR
a. Statutorily no
compulsion
for Side
bolting to be
included in
SSR
a. SSR design
horizontal stress
are not considered
a. Working at
shallow depth
does not have
effect due to
horizontal stress.
a. Introduction
side bolting
and wire
netting at
depth more
than 300
Meters.
Jharia Division 23
Counter measures taken
Causes Counter measures Mitigation Method
a.Improper
roof Support
(Geo -
physical
properties)
a.Joint R&D with CIMFR to assess
the Rock Mass Rating of the roof.
b.Use of Resin Capsule
c.Systematic Support Rules (SSR)
revised and is based on Rock Mass
Rating.
d.Design of Roof Bolt Changed.
a.Fail Safe
b.Fool proofing
c.Fail Safe
d.Fool proofing
a.Inadequate
Side Support
a.Introduction side bolting and wire
netting at depth of more than 300
meters.
a.Fail Safe
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division 26
Key Issue and Action Taken- Roof and Side fall
Area Key Initiatives and efforts In- Process Effects
Strata
Control
System
Replaced 1.9m roof bolts by 2.4 metres Reduction in damage of immediate strata.
Replaced cement capsule by Resin
Capsule
Increase in load bearing capacity up to 10 ton and
better strength in watery condition
Introduced Cable bolting of 5 metres long Increase in percentage of extraction in depillaring.
Introduced Strata Condition monitoring
instrumentation (Load cell, Tale tell &
convergence recorder)
Auto Warn: Introduced first time in India, and is a
visual warning system. It gives early warning before
strata failure.
Load cell, Tale tell
26
Jharia Division 27
Key Issue and Action Taken- Human Interface
Area Key Initiatives and efforts In- Process Effects
Improving
Mechaniz
ation
8 Nos of LHDs to replace 16 Nos of SDLs Reduction in manpower exposure to mining
hazards.
Manual drilling practice has been completely
replaced by roof bolting machine
Reduction in fatigue of persons due to manual
drilling in roof
4 Nos of UDM have been deployed for
drilling
Exposure of person at face is completely eliminated
To eliminate blasting, one Road Header has
introduced in phase wise.
Damage of strata due to blasting is eliminated
Tub mining has been replaced with belt
conveyor at one unit
Hazard of tub mining eliminated
LHD
UDM
Road header
BEFORE : Manual Drilling of
Holes for roof bolting
AFTER: Mechanized
Drilling of Hole
LHD- Load Haul Dumper, SDL- Side Discharge Loader, UDM- Universal Drill Machine 27
Jharia Division 28
Key Issue and Action Taken- Fatigue
Area Key Initiatives and efforts In- Process Effects
Improving
working
conditions at
Underground
Deployment of Manrider in underground
colliery
Reduction in fatigue due to arduous traveling
Use of higher capacity auxiliary fans of 600
cum/min started for better ventilation
Quantity of air at face increased resulted in
reduction in face temperature from 34º to 31º C
6 Nos of staple pits have been made at
Sijua, Digwadih & 6&7 Pits Colliery
Resistance in ventilation circuit reduced resulted in
increased in quantity of air
Old MMV of 5000 cum/min capacity have
been replaced with new MMV of 8000
cum/min capacity at Sijua Colliery
Total air quantity at Sijua improved by 50 %
Man
riding
Hand Rail
600 Cum
Auxiliary
Fan
MMV- Main Mechanical Ventilator 28
Jharia Division 29
2
4 3
0 1 2
4
0
2.5
5
7.5
10
FY05 FY06 FY07 FY08 FY09 FY10 FY11Fata
l A
ccid
en
ts
Raw Materials Division Jharia
Roof / Side Support
• Design of Roof Bolt
• Use of resin
capsule
• Scientific Study
(RMR)
Based on past years analysis : 60% of Fatal
Accident cause due to Roof / Side Fall in
Underground near working Face
FATAL ACCIDENT – RMD & JHARIA
Journey on Safety at Jharia
In spite of action taken in FY10 to arrest roof fall/Side fall there were accident in
FY11.
Jharia Division 30
FY11 Fatal Accident analysis
0 1
SDL running withoutcanopy
Crossing BeltConveyor
Drowning Bystowing water
Electrocution
Main Cause of Fatal Accident in FY-11
SOP not
followed
SOP not
followed
SOP not
followed
Process
Failure
Behavior
al Issue
In FY10 behavioral issues were not addressed which cause accident in FY11.
In FY’11 more focus on behavioral issues
3
1
0
1
2
3
4
5
Fatal Accident
ProcessFailure
SOP NotFollowed
Jharia Division 31
To address the Issue following action have been taken
• Restructuring of safety organization was done
• To give more autonomy to department
• For faster implementation of the recommendations
• Safety Dash Board was revised to incorporate FRCP and ECAUP
( Several New KPIs has been added)
Enhance Safety Excellence Journey
Jharia Division 32
Enhance Safety Excellence Journey
New KPIs Added for DIC Review
SL Action
Type Safety KPIs Unit of Measure
1
Be
ha
vio
ral
Employees identified violating life saving rule and disciplined No. of employees
2 Employees identified violating safety rules and disciplined No. of employees
3 Safety programs conducted for house wives Nos.
4 Safety programs conducted involving school children at pit
heads Nos.
5 Mass meetings chaired by senior management Nos.
6 Monthly Campaign on Safety Nos.
7 Safety Drama at Pit top and colonies Nos.
7
Fail
Safe
& F
oo
l
pro
ofi
ng
CAUPs identified & Mitigated Nos.
8 FRCPs identified & rectified Nos.
9 FRCPs identified related to unsafe acts Nos.
10 SOPs developed with visuals Nos.
11 SOPs revised as per JCC Nos.
12 Employees trained on positive isolation No. of employees
13 Employees trained to improve skill No. of employees
14
Mech
an
iza
tio
n
Employees removed from hazardous place through
mechanization No. of employees
15 Safety schemes proposed Nos.
Additional New Safety KPIs for Enhance Safety Excellence Journey
Jharia Division 33
Status of main KPIs of ESEJ
S.
No. KPI UOM
Mar’ 12 Apr 11 to Mar’ 12 Remarks
Plan Actual Plan Actual
1 CAUPs identified Nos. 5 5 89 99
2 CAUPs mitigated Nos. 20 24 78 82
3 Employees identified violating
life saving rule and disciplined
No. of
employees 5 23 60 44
4 Employees identified violating
safety rules and disciplined
No. of
employees 5 25 60 362
5 FRCPs identified Nos. 7 2 84 93
6 FRCPs rectified Nos. 7 1 84 73
7 FRCPs identified related to
unsafe acts Nos. 1 0 10 10
8 SOPs developed with visuals Nos. 1 2 12 12
9 SOPs revised as per JCC Nos. 2 2 10 10
10 Employees trained on
positive isolation
No. of
employees 0 0 100 % 100%
Jharia Division 34
S.
No. KPI UOM
Mar’ 11 Apr 11 to Mar’12 Remarks
Plan Actual Plan Actual
11 Employees trained to improve
skill
No. of
employees 65 65 780 925
12 Safety programs conducted for
house wives Nos. 1 1 4 5
13 Safety programs conducted
involving school children Nos. 1 1 5 7
14 Mass meetings chaired by GM Nos. 2 2 19 19
15
Employees removed from
hazardous place through
mechanization
No. of
employees 20 20 20 20
16 Safety schemes proposed Nos. 1 1 6 5
Status of main KPIs of ESEJ (contd..)
Jharia Division 35
Jharia Division 36
Safety awareness Program conducted involving school children
Changing behavior:
Messaging through School children and Family
36
Jharia Division 37 37
Apex safety Council
Meeting, Chaired By
MD
DIC(RM) Chaired By
VP
DIC(JH) Chaired By
GM
AIC ( Sijua
Group),
Chaired By
DGM
AIC (
Jmb
Group),
Chaired
By Chief
Standard
Safety
Committe
e meeting
Observat
ion and
Audit sub
committe
e
Incident
Investigati
on sub
Committe
e
Contract
or safety
Sub
Committ
ee
OHS
Commi
ttee
Training
and
Communi
cation sub
Committe
e
Head
Safety
Safety
Officers
Enhance Safety Excellence Journey – Revised safety organizational
structure
Changes in safety
organizational structure
Jharia Division 38
38
“ JAGRAN” Program “ JAGRAN” Program
Awareness Program on Anemia Control Rolling our Anemia Control Program
Changing behavior: Life Style management program
Jharia Division 39
Key Issue and Action Taken- Behavioral Issue
Area Key Initiatives and efforts In- Process Effects
Behavioral
Safety
Safety awareness & communication programs
organized on TAKE 5 , Safety is My
Responsibility, “ Find It-Own It- Fix It”
Safe act index improved from 65% to 74%
Joint Mass Communication are being organized
along with Union on regular basis
Employees participation in safety improved
Incident based communication films Learning from past incidents to prevent re-
occurance of such incidents
Safety through community
(Khushali, SAFE CLUB)
To inculcate safety culture among school
children, community and family members
Sumilan Program was organized for contractors Contractors safety competency development
CP
R 39
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division 42
4.18
4.84
1.30 1.00
0.70 0.40
0.40
0.40 0.40
4.18
4.84
0.48 0.49 0.80 0.86
0.32 0.44
0.65 0
1
1
2
2
3
3
4
4
5
5
FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
LTIF
R -
Jh
aria
Plan Actual
2
4 3
0 1 1
4
0 0 1
0 0
2
4
6
8
10
FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
Fatal Analysis Trend
LTIFR Trend (FY07-FY15)
Effect
LTIFR- Loss Time Injury Frequency Rate
Safety Excellence journey
Enhanced Safety Excellence journey
Jharia Division
Greentech Safety
award 2015 for Gold
Category
National safety award by Honourable President of India, Mr. Pranab Mukherjee
awarded to Digwadih Colliery & Jamadoba Colliery
Tata steel Jharia Division Rescue team won 1st
Runner up Prize in 48th Zonal Mines Rescue
competition held at MRS, Dhansar.
Tata Steel Rescue team participated in 9th
International Mines rescue competition held at
Poland.
Key Achievements in Safety in Fy’15
Jharia Division 44
6 & 7 Pits Bhutgoria
Amalgamated Colliery won
overall prize
Sijua Colliery won 1st
Runner’s up prize
Tata Central Hospital Jamadoba
won best occupational health
center.
In Annual Mines Safety Week
2014 Jharia Division won total 29
prized in various categories.
Jharia Division Rescue team won
2nd Prize in 45th All India Mines
rescue competition held at MRS
Ramgarh
In Annual Mines Safety Week
2014 Jharia Division won total
29 prized in various categories.
Achievements in Annual Mines Safety Week
Key Achievements in Safety in Fy’15
44
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Agenda
Background
Safety in Indian Mining
Analysis of accidents in underground mines of TATA Steel
Implementing Remedial Measures
• Engineering Solutions
• Transforming People
Effect
Future Plans
Jharia Division
Initiative Timeline
Sinking/ Deepening Of Shafts FY18
Installation of Mine Air Conditioning System FY16
Introduction of Mass production technology (Continuous Miner) FY17
Installation of Man Riding systems FY17
Installation of higher capacity auxiliary fan FY17
47
Future Mechanization Plan – Improving Working Condition
Jharia Division 48
Jharia Division
49
Jharia Division 50
4.18 4.84
1.30 1.00
0.70 0.40
4.18 4.84
0.48 0.49
0.80 0.86
0.00
2.00
4.00
6.00
FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12
Rat
e
Plan ActualBehavioral
Safety
Managemen
t
Process
Safety &
Job Cycle
Check
2
4 3
0 1 2
4
2
2
4 3
1 1
4
0
0
2.5
5
7.5
10
FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12
Fata
l Acc
iden
ts RMD Jharia
LOSS TIME INJURY FREQUENCY RATE – JHARIA
FATAL ACCIDENT – RMD & JHARIA
OHSAS
18001
SEZ
with
DuPont
Overall Effects
Zero
Fatality
Jharia Division 51
4.18 4.84
1.30 1.00
0.70 0.40
0.40 0.40
0.40
4.18
4.84
0.48 0.49 0.80 0.86
0.32 0.44
0.65 01122334455
FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
LTIF
R -
Jh
aria
Plan Actual
2 4 3
0 1 1
4
0 0 1 0 0
2
4
6
8
10
FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
7
2
1 1 1 1 1 1 1
0
1
2
3
4
5
6
7
8
Roof F
all
Tu
bM
ovem
ent
Dro
win
g in
sto
win
gin
clin
e
Fa
ll in
sto
win
g lift
SD
Lru
nnin
gw
ith
out
can
opy
Dro
win
g a
tF
ace
Cro
ssin
gove
r belt
Not
follo
win
gP
ositiv
eIs
ola
tio
n
Po
or
Housekeep
ing
Cause Wise Fatality
Root Cause:
1. Hazardous working condition:
Roof and Sides
High Man- M/c. Interface
Arduous environmental condition
and traveling roadway
2. Behavioral issues:
Lack of Safety awareness
Lack of safety competency in
hazard identification.
Low literacy level
Disciplinary issues
Fatal Analysis Trend
LTIFR Trend (FY07-FY15)
Analysis of accidents at Jharia
LTIFR- Loss Time Injury Frequency Rate
27%
10%
21%
16%
14%
8%
All Incidences FY’15
Hit by Object
Fall of Object
Slip of Person
Fall of Person
Roof Fall
Side Fall
Others
51
Jharia Division 52 52