CHAVARA ILMENITE MINE & VELLANATHURUTHU ILMENITE...

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SAFETY MANAGEMENT PLAN (SMP)

CHAVARA ILMENITE MINE & VELLANATHURUTHU ILMENITE MINE

M/S IRE LTD

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INDEX

SL. NO.

TOPIC PAGE NO.

1 Abbreviations 3-4

2 Health & Safety Policy 5

3 Introduction 6

4 Responsibility, Authority & Accountability 7-10

5 Safety Committee 11-12

6 Safety Management Plan 13-35

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ABBREVIATIONS

SL. NO. ABBREVIATION STANDS FOR

1. ADM. BLDG Administrative Building

2. AEE Assistant Electrical Engineer

3. AM Assistant Manager

4. AME Asst. Mechanical Engineer

5. ASST. Assistant

6. CCC Central Control Centre

7. CER Civil Engineer

8. CMO Chief Medical Officer

9. CoP Code of Safe Practices

10. DEPT Department

11. DGC DGMS Circulars

12. DGMS Directorate General of Mines Safety

13. DMG Department of Mines & Geology

14. DWUP Dredge & Wet Upgradation Plant

15. ECP Emergency Control Plan

16. EE Electrical Engineer

17. EIP Emergency Initiation Protocol

18. ERCI Existing Risk Control Index

19. ES Electrical Supervisor

20. ETP Effluent Treatment Plant

21. FM Foreman

22. FME Foreman (Electrical)

23. FMM Foreman (Mechanical)

24. FO Furnace Oil

25. HAZ. Hazard

26. HEMM Heavy Earth Moving Machinery

27. HIRA Hazard Identification & Risk Assessment

28. HOD Head of Department

29. HPU Health Physics Unit

30. hr. Hour

31. HRM Human Resource Management

32. HSD High Speed Diesel

33. IA Immediate Action

34. IAF Immediate Action Flag

35. IBM Indian Bureau of Mines

36. ICC Incident Control Centre

37. ILO International Labour Organisation

38. Int. Intercom

39. ISO International Organisation for Standardisation

40. ISO Internal Safety Organisation

41. K.M Kilometer

42. LAB Laboratory

43. 11 KV SS 11 KV Substation

44. LPG Liquefied Petroleum Gas

45. Maint. Maintenance

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SL. NO. ABBREVIATION STANDS FOR

46. MCC Motor Control Centre

47. ME Mechanical Engineer

48. Med Medium

49. MES Mechanical Supervisor

50. MG Management Guidelines

51. MM Mines Manager

52. MO Medical Officer

53. MoEF Ministry of Environment, Forest & Climate Change

54. MSDS Material Safety Data Sheet

55. MSP Mineral Separation Plant

56. OHS Occupational Health and Safety

57. KSPCB Keralaa State Pollution Control Board

58. PPE Personal Protective Equipment

59. P&T Post & Telegraph

60. Q. A Quality Assurance

61. QSS Quality System Secretariat

62. RA Risk Assessment

63. Reg Metalliferous Mines Regulations, 1961

64. Res Responsibility

65. RL Reduced Level

66. RSP Relevant Statutory Provisions

67. Rul(T) Mine Vocational Training Rules, 1966

68. S & T Safety and Training

69. SMP Safety Management Plan

70. SO Safety Officer

71. SOP Safe Operating Procedure

72. SUR Surveyor

73. SURO Survey Officer

74. SWP Safe Working Practices

75. TARP Trigger Action Response Plan

76. Tel. No Telephone Number

77. T.S Technical Service

78. TTI Technical Training Institute

79. WI Work Instruction

80. WIE Workman Inspector (Electrical)

81. WIM Workman Inspector (Mining)

82. WIME Workman Inspector (Mechanical)

83. WS Workshop

84. YF Yellow Flag

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QUALITY, ENVIRONMENT, OCCUPATIONAL HEALTH & SAFETY POLICY

We at IREL, Chavara are committed to sustain our growth in the supply of beach

sand minerals and mineral products through :-

Product Quality.

Customer Satisfaction.

Prevention of Pollution.

Conservation of Natural Resources.

Compliance with Legal Requirements.

Prevention of Accidents & Ill-health.

Safe Working Environment and

Continual Improvement.

-sd-

Date: 01.01.2009 Unit Head

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INTRODUCTION

Name of the Mine Chavara Ilmenite Mine M/s Indian Rare Earths Limited

Vellanathuruthu Ilmenite Mine M/s Indian Rare Earths Limited

LIN No 1-1860-6271-8 1-8137-1230-7

Mine Code 480001

Name of the Owner Sri Deependra Singh, CMD Sri Deependra Singh, CMD

Name of the Agent Sri S. Surya Kumar, CGM & Head, IREL, Chavara

Sri S. Surya Kumar, CGM & Head, IREL, Chavara

Name of the Manager Sri S.Jayachand, CM (Mining) Shri S.Anandapadmanabhan, Manager (Mining)

Location Chavara, Neendakara, Kollam District, Kerala

Alappad, Panmana, Ayanivelikulangara, Karunagapally Taluk, Kollam District, Kerala

Distance from nearest Railway Station

12 kms 10 kms

Mining Lease Area 129.204 ha 220.566 ha

Type Opencast Mechanized Mine Opencast Mechanized Mine

Mineral Ilmenite, Rutile, Zircon, Monazite, Leucoxene and Sillimanite

Ilmenite, Rutile, Zircon, Monazite, Leucoxene and Sillimanite

HEMM Dredger, TOYO pump, Loader, Excavator, Tipper

Dredger, TOYO pump, Loader, Excavator, Tipper

Mining Capacity 6,38,000 tonnes of raw sand per annum

10,37,150 tonnes of raw sand per annum

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RESPONSIBILITY, AUTHORITY & ACCOUNTABILITY

The responsibility, authority and accountability of personnel managing, performing and verifying

work affecting the systems are defined through functional responsibilities, authority and

accountability.

FUNCTIONAL RESPONSIBILITY, AUTHORITY AND ACCOUNTABILITY

a. Owner is responsible for:

1. Carrying out responsibilities as specified in the Mines Act, Regulations and Rules.

2. Overall Responsibility of all mines working under him.

3. Providing resources for implementing

4. Providing all necessary inputs to carry out smooth functioning of mines.

b. Agent is responsible for:


2. Overall Responsibility of the Plant including Mines.

3. Conducting regular review meeting for Production, Safety, Quality & Environment.

4. Scrutinizing & Approving Annual Production Budget.

5. Maintaining liaisoning with regulatory authorities.

6. Long Term Mine Planning & introduction of New Mining Technologies.

7. Establishing policies for each system.

8. Providing necessary resources, Manpower & Infra structure for meeting long term

targets.

9. Conducting Management Review for assessing adequacy and effectiveness of system &

initiate corrective actions.

c. Manager is responsible for:


2. Mines overall activity.

3. Defining organization structure, responsibilities, authority and interrelationships for

fulfilling the requirements of the systems.

4. Preparing production budget and getting approval from management.

5. Maintaining liaison with regulatory authorities.

6. Coordinating with all external agencies and interdepartmental activities.

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7. Long term mine planning and introduction of new mining technologies

8. Carrying out the duties as per Regulation No.44 of MMR 1961

9. Coordinating and reviewing the activities of all departments to achieve optimum results;

scrutinizing and approving of purchase indents.

10. Assessing need for infrastructure, resources, manpower and submit the same to Agent

for approval to meet annual targets.

11. Any additional duties assigned by Agent of Mines.

d. Asst. Manager – Mining is responsible for:


2. Assisting Mines Manager in running the mine and in the absence of Mines Manager,

Assistant Manager shall have the same responsibility, discharge the same duties and be

subject to the same liabilities as the manager.

3. Ensuring that all work is carried out in accordance with the provision of the Act and

regulations, rules, bye laws made under.

4. Performing the duties as per Regulation No.45 of MMR 1961.

5. Short term / Long term mine planning.

6. Preparing & Submitting data required for budget proposal.

7. Identifying the legal requirements and ensure compliance in respect of all tasks &

operations.

8. Forwarding necessary returns to statutory bodies in time.

9. Obtaining all necessary statutory permissions.

10. Ensuring renewal of necessary licenses and permits.

11. Qualitative and Quantitative feeding to processing plants.

12. Ensuring implementation of SOPs, emergency preparedness & emergency response.

13. Checking all reports, registers and other records; countersign the same with date.

14. Maintaining in a bound-paged book kept for the purpose, a diary, and also shall record

therein the findings of each of his inspections and also the action taken by him to rectify

the defects mentioned, if any.

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e. Engineer – Electrical is responsible for:

1. Holding general charge of all machinery at the mine and the proper installation,

maintenance and safe working of such machinery.

2. Performing duties specified under Regulation no.53 of MMR 1961 and CEA (Measures

relating to Safety & Electric Supply) Regulations, 2010

3. Ensuring optimum availability of machinery/ electrical energy.

4. Maintaining history sheets of different log book, statutory records and other registers

pertaining to all the machinery.

5. Planning and ensuring preventive and scheduled maintenance.

6. Prompt repair of breakdown of machinery.

7. Planning and ensuring availability of necessary spares & allocating of duties for shift

personnel.

8. Furnishing all documents necessary for insurance claim if any in case of accident or

otherwise.

9. Warranty claim of spares.

10. Maintaining liaison with electricity board officials.

11. Ensure preparation & Submission of annual returns to DGMS as per CEA (Measures

relating to Safety & Electric Supply) Regulations, 2010

f. Engineer – Mechanical is responsible for:

1. Holding the general charge of all machinery at the mine and the proper installation,

maintenance and safe working of such machinery.

2. Performing duties specified under Regulation no.53 of MMR 1961.

3. Ensuring optimum availability / Reliability of machines.

4. Planning and ensuring preventive and scheduled maintenance,

5. Ensure prompt repair of breakdown machinery.

6. Planning and ensuring availability of necessary spares.

7. Reviewing all documents necessary for insurance claim if any in case of accident or

otherwise.

8. Warranty claim of spares.

9. Responsible for the overall responsibility of Installation,

10. Maintenance and repair of the machines.

11. Ensuring compliance of all safety laws & SOPs in respect of installation or maintenance

of machinery.

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12. Responsible for editing, deleting of existing SOPs and also for framing of new SOPs

13. Coordinating with AMC people for prompt maintenance of machinery

g. Mines Surveyor is responsible for:

1. Carrying out duties as mentioned in Regulation No.52 of MMR 1961.

2. Survey and preparation of surface plans, working plans and sections including all those

required under regulations 61 of MMR 1961.

3. Surveying and giving profile planning for main roads, electric line in the mine area.

4. Measuring and marking the mine boundary on mine plans

5. Constructing and maintaining boundary pillars all along the mine boundary.

6. Updating the profile of working areas

h. Mines Foreman is responsible for:

1. Performing duties as per Regulation 46 of MMR 1961.

2. Allocated machinery, personnel & vehicles according to the instructions of Asst. Mines

Manager.

3. Check and ensure that no person is allowed into the workings or to operate any machine

if found under the influence of drink/drug.

4. Ensure that all mine roads are of adequate width and gradient.

5. Ensuring the safe working of men and machinery.

6. Giving prompt attention to the removal of any danger observed by or reported to him,

and shall see that dangerous places are adequately fenced off.

7. Rendering First Aid and arranging transportation to hospital & informing his superiors in

case of an accident.

8. Maintaining a bound paged record book covering all aspects of his duties performed in

his shift.

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SAFETY COMMITTEE

The functions of the Safety Committee is as follows (As stipulated in Rule 29V of Mines Rules, 1955)

1. To discuss remedial measures against the unsafe conditions and practices in the mine as

pointed out in the reports of Workmen’s Inspector or otherwise brought to the notice of the

committee and make appropriate recommendations.

2. To consider, before commencement of operations in any part of the mine or commissioning

of new electrical or mechanical installation or introduction of new mining technique, the

proposed safety and health measures including related codes or practice and to make

appropriate recommendations.

3. To discuss the report of inquiry into accidents/incidents and make appropriate

recommendations.

4. To formulate and implement appropriate safety campaigns based on analysis of accidents.

5. To meet at least once in thirty days to consider the matter placed before it and any other

matter that may be raised by the members and make such recommendations as it may

deem fit; and

6. To serve as forum for communication on safety and occupational health matters.

All the recommendations of the safety committee are implemented. The minutes of every meeting is

recorded and are kept updated every month.

Members of Safety Committee :

Sl. No. Name S/Shri

Designation Department Status

1 S.Surya Kumar CGM & Head, Chavara. Chavara Chairman

2 Dr.M.D.Adis Miranda DGM (Medical) Medical Member

3 R.V.Viswanath DGM (TS) Production Member

4 Lingaraj Patnaik DGM (S, E & T) Safety Member Secretary

5 Varghese Antony DGM (Maintenance) Maintenance Member

6 S.Jayachand CM (Mining) Mining Member

7 V.Chandrasekar DGM (S,E,F,RS) Radiation Safety

Member

8 K.Ajithkumar CM (Electrical) Electrical Member

9 Balamuraleekrishnan CM (Civil) Civil Member

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Sl. No. Name S/Shri

Designation Department Status

10 John D Padua Workmen, Card No.1313 Maintenance Member

11 E.Nazerkutty Workmen, Card No.912 Production Member

12 G.Sajeevan Workmen, Card No.1355 Production Member

13 V.Anilkumar Workmen, Card No.1322 Production Member

14 N.Udayakumar Workmen, Card No.1238 Maintenance Member

15 K.Anilkumar Workmen, Card No.1436 Maintenance Member

16 Mohammed Ali Workmen, Card No.1315 Maintenance Member

17 L.Thulaseedharan Workmen, Card No.1237 Maintenance Member

Invitees

18 Ramesh Prabhu DGM (S&D) Stores Invitee

19 K.R.Sreelal CM (Mechanical) Maintenance Invitee

20 G.Kochu Thampi Workmen Inspector (Elec) Maintenance Invitee

21 G.Babu Workmen Inspector (Elec) Maintenance Invitee

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SAFETY MANAGEMENT PLAN

1-INTRODUCTION

It is a systematic, explicit and comprehensive process for managing safety risks. As with

all management systems, a safety management system provides for goal setting, planning, and

measuring performance. Define how the organization is set up to manage risk. Identify workplace

risk and implement suitable controls.

Safety management plan (SMP) is a strategy of us for management of safety and health of people

who works at the mine .It addresses liability issue of owner, agent and manager. It is a working

documents fundamental to the management of safety, which outlines all the actions to the carried

out to ensure the safety and health at the work place.

2-PURPOSE OF PLAN

Safe, health conscious and environmentally responsible systems of work.

Effective participation and consultation with employees.

Effective management of hazards.

Early reporting of incidents and thorough investigation.

Measurement, evaluation, auditing and continuous improvement.

3 SCOPE

This document is designed to meet the requirements of DGMS (Tech.) S&T Circular no.05

dated 2nd April 2016. The ninth and tenth Conference on Safety in mines has recommended

adopting Risk Assessment as a tool for development of appropriate health & safety

management systems in Indian mines. The eleventh Conference further recommended that

the managements of every mining company should adopt the process of safety management

system and commit itself for proper formulation and implementation of the same in totality.

Drawing inputs from inferences drawn from several workshops on "Risk Assessment" in Indian

mines conducted by DGMS, a document on "Safety Management System - A guideline for

implementation" was prepared and circulated as DGMS(Tech)(S&T) Circular No. 13 of 2002.

Another guideline in this regard titled "Safety Management System Provision for auditing and

review" was issued by DGMS as DGMS (Tech) (S&T) Circular No. 02 of 2011.

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4 Hazard Identification and Risk Management

4.1 Some Frequent Used Definition

Hazard is a source of potential harm, injury or loss.

RISK is combination of the likelihood of a specific unwanted event and the potential

consequences should it occur.

Risk Score = Consequence x Likelihood

Likelihood = Exposure x Probability

So, Risk Score = Consequence x Exposure x Probability

CONSEQUENCE: It is the Severity/Intensity/ Impact of loss or damage to Man, Material

& Machine.

EXPOSURE: It is used as a % of time a person is exposed to hazard.

PROBABILITY: It is defined as the chances that persons will be harmed.

LIKELIHOOD: It is multiplication of Exposure and Probability.

RISK ASSESSMENT is a process that involves measurement of risk to determine

priorities and to enable identification of appropriate level of risk.

RISK RATING is a category or level of risk assigned following risk assessment.

RISK CONTROL is an implementation of strategies to prevent or control hazards.

RISK MANAGEMENT is an overall description of the steps taken to manage risk by

identifying hazards and implementing control in the workplace.

RISK ASSESSMENT PROCESS is a methodical examination of each and every aspect of

work undertaken on a regular basis of identity hazards, determine risk rating and

controls and to review the implementations of risk controls from previous risk

assessment process.

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4.2 Risk Assessment & Ranking

Estimation of consequence, Exposure and Probability for each of the previously

identified hazard and assigning them quantitative values.

By multiplying these 3 factors ,a range of risk raking are obtained

Risk Score = Consequence x Likelihood

Risk Score = Consequence x (Exposure x Probability)

Risks are ranked according to level of risk i.e. highest to lowest, which enables one to

establish risk which need immediate attention or may be managed in ongoing manner.

Categorize --------

Risk Score Action to be taken Categorisation of Risk

Risk score > 200 Requiring Immediate attention High Risk

Risk score < 200 & >20 Requiring Management Action Medium Risk

Risk score < 20 to be watched and reviewed Low Risk

Table-1 : Scale for Percentage of work persons employed

Serial No

Percentage of work persons employed

Impact assessment of exposure

1 >40 Maximum

2 20-40 High

3 10-20 Medium

4 5-10 Low

5 < 5 Very Low

Table-2 : Scale for Consequence

Several Dead 5

One Dead 1

Significant chance of fatality 0.3

One permanent disability

Or

Less chance of fatality

0.1

Many lost time injuries 0.01

One lost time injury 0.001

Small injury 0.0001

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Table-3 : Scale for Exposure

Continuous 10

Frequent (Daily) 5

Seldom (Weekly) 3

Unusual (Monthly) 2.5

Occasionally (Yearly) 2

Once in 5 years 1.5

Once in 10 years 0.5

Once in 100 years 0.02

Table-4 : Scale for Probability

May well be expected 10

Quite Possible 7

Unusual but Possible 3

Only remotely Possible 2

Conceivable but unlikely 1

Practically Impossible 0.5

Virtually Impossible 0.1

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Table-5 : Initial hazard identification

Haz. No. Description of Hazard % of workers exposed

Consequence (C)

Exposure (E)

Probability (P)

Total Risk (C*E*P)

Risk Level

H 1 Working at height < 5 5 5 10 250 High

H 2 Operation of Dredge & Upgradation unit < 5 5 10 7 350 High

H 3 Fire < 5 5 10 7 350 High

H 4 Loading & Transportation of mineral < 5 5 10 7 350 High

H 5 Electrical Maintenance < 5 5 10 7 350 High

H 6 HEMM operation < 5 5 5 7 175 Medium

H7 Structural failure < 5 5 10 3 150 Medium

H 8 Maintenance of HEMM < 5 5 5 3 75 Medium

H 9 Running/ rotating machines < 5 1 10 7 70 Medium

H 10 Noise < 5 0.3 10 3 9 Low

H 11 Lack of communication system < 5 0.3 10 3 9 Low

H 12 Lack of skilled persons & Improper supervision

< 5 0.3 10 3 9 Low

H 13 Anchor shifting < 5 0.3 5 3 4.5 Low

H 14 Welding & Gas cutting < 5 0.3 5 3 4.5 Low

H 15 Lack of illumination < 5 0.3 5 3 4.5 Low

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Table-6 : Hazard identified as HIGH risk (Risk score > 200)


Consequence (C)

Exposure (E)

Probability (p)

Total Risk (C*E*P)

Risk Level

H 1 Operation of Dredge & Upgradation unit < 5 5 10 7 350 High

H 2 Fire < 5 5 10 7 350 High

H 3 Loading & Transportation of mineral < 5 5 10 7 350 High

H 4 Electrical Maintenance < 5 5 10 7 350 High

H 5 Working at height < 5 5 5 10 250 High

Table-7 : Hazard identified as MEDIUM risk (Risk score < 200 and > 20)


Consequence (C)

Exposure (E)

Probability (p)

Total Risk (C*E*P)

Risk Level

H 6 HEMM operation < 5 5 5 7 175 Medium

H7 Structural failure < 5 5 10 3 150 Medium

H 8 Maintenance of HEMM < 5 5 5 3 75 Medium

H 9 Running/ rotating machines < 5 1 10 7 70 Medium

Table-8 : Hazard identified as LOW risk (Risk score < 20)


Consequence (C)

Exposure (E)

Probability (p)

Total Risk (C*E*P)

Risk Level

H 10 Noise < 5 0.3 10 3 9 Low

H 11 Lack of communication system < 5 0.3 10 3 9 Low

H 12 Lack of skilled persons & Improper supervision

< 5 0.3 10 3 9 Low

H 13 Anchor shifting < 5 0.3 5 3 4.5 Low

H 14 Welding & Gas cutting < 5 0.3 5 3 4.5 Low

H 15 Lack of illumination < 5 0.3 5 3 4.5 Low

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Table-9 : Summarised hazard identification

(High & Medium risk hazards with Sub-category of hazard)

Haz. No. Hazard Sub-category of Hazard

H 1 Operation of Dredge & Upgradation unit Fall or Slip of persons into Pond Water

Electric shock

Fall of person from height

Slip due to oil spillage

Fall of materials from height

H 2 Fire General Fire

Electrical Fire

Fire in HEMM

Fire in buildings/ stores/ inflammable material storage

Fire/ explosion of diesel dispensing pumps

Fire/ explosion of industrial gas cylinders

H 3 Loading and transportation of mineral Accidents while reversing of vehicles

Toppling of machine

Equipment collisions

Exposure to Dust

Exposure to Noise

H 4 Electrical Maintenance Fire Hazard

Electrocution

H 5 Working at height Fall of person from height

Fall of object from height

H6 HEMM operation Hitting by Loader / tipper

Toppling of Loader / tipper

Exposure to Dust

Exposure to Noise

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Haz. No. Hazard Sub-category of Hazard

H 7 Structural failure Failure of plant structure

Failure of structures of office building

Failure of overhead structures/ facilities (EOT cranes, etc.)

H 8 Maintenance of HEMM Machinery Hazard

Chemical Hazard

Fire Hazard, Burn & Scald Hazard

Gravity Hazard

H 9 Running/ rotating machines Running machines, Rotating drives, gears, belts and couplings

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Table-10 : Risk Assessment

Hazard identification as regards to : Operation of Dredge & Upgradation Unit (H 1)

Haz. No..

Sub-category of Hazard Mechanisms Calculated Risk Risk Rating Comments

Consequence Exposure Probability Risk Level

1 Fall or Slip to Pond Water While walking on pontoons 5 10 7 350 High

2 Electric shock While working with overhead EOT crane, electrical maintenance of panels, transformers

5 10 7 350 High

3 Fall of person from height While cleaning cutter/ bucket-wheel, spirals, spiral distributors, while carrying out maintenance near trommel area

5 10 7 350 High

4 Slip from oil spillage While doing maintenance of dredge pump, hydraulic machines, winches

5 10 7 350 High

5 Fall of materials from height

While handling pumps, motors etc. by chain pulley

5 10 7 350 High

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Hazard identification as regards to : Fire (H 2)

Haz. No..



1 General Fire Presence of inflammable material, static electricity, thunderstorm, electronic items

5 10 7 350 High

2 Electrical Fire Electrical short circuits or malfunction of safety devices

5 10 7 350 High

Poor maintenance and inspection 5 10 7 350 High

3 Fire in HEMM Electrical short circuits or malfunction 5 10 7 350 High


4 Fire in buildings/ stores/ inflammable material storage

Electrical short circuits or malfunction 5 10 7 350 High

Poor maintenance, inspection and improper storage

5 10 7 350 High

5 Fire/ explosion of diesel dispensing pumps

Deviation from permitted conditions 5 10 7 350 High

Presence of inflammable material, static electricity, thunderstorm, electronic items

5 10 7 350 High

6 Fire/ explosion of industrial gas cylinders

Lack of knowledge and skill 5 10 7 350 High

Electrical short circuits or malfunction 5 10 7 350 High



5 10 7 350 High

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Hazard identification as regards to : Loading & Transportation of mineral (H 3)

Haz. No..



1 Accidents while reversing of vehicles

Absent-mindedness of workmen, Failure of audio-visual alarm, Accidental hits to workmen/equipment nearby while reversing

5 10 7 350 High

2 Toppling of machine During working at face, Speedy movements especially along wet roads, Sudden failure of brakes, Steering failure

5 10 7 350 High

3 Equipment collisions Close movements at mine faces and haul roads – especially during overtaking situations, Sudden failure of brakes, Lack of visibility during monsoon period, Wet conditions with water accumulations on roads & faces

5 10 7 350 High

4 Exposure to Dust Dust generated during working in dry faces & haul roads

0.3 10 10 30 Medium

5 Exposure to Noise Noise generated during operations 0.3 10 7 21 Medium

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Hazard identification as regards to : Electrical Maintenance (H 4)

Haz. No..



1 Fall Hazard Fall of persons from height during 11 kV line maintenance, maintenance of lighting towers

5 5 10 250 High

2 Electrocution Electric shock during operation & maintenance of transformer, DG sets, Sub-stations, motors

5 10 7 350 High

Hazard identification as regards to : Working at height (H 5)

Haz. No..



1 Fall of person from height While going up or getting down from height 5 5 10 250 High

2 Fall of object from height While fixing sheets or executing painting work

5 5 10 250 High

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Hazard identification as regards to : HEMM operation (H 6)

Haz. No..



1 Hitting by Loader Accidental collisions during operating/maneuverings

5 5 7 175 Medium

2 Toppling of Loader Working at slopes or face edges 5 5 7 175 Medium

3 Exposure to Dust Dust generated during operation 0.3 10 10 30 Medium

4 Exposure to Noise Noise generated during operation 0.3 10 7 21 Medium

Hazard identification as regards to : Structural Failure (H 7)

Haz. No..



1 Failure of plant structure Failure of plant structure 5 10 3 150 Medium

2 Failure of structures of office building

Failure of structures of office building 5 10 3 150 Medium

3 Failure of overhead structures/ facilities (EOT cranes, etc.)


5 10 3 150 Medium

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Hazard identification as regards to : Maintenance of HEMM (H 8)

Haz. No..

Sub-category of Hazard Mechanisms Calculated Risk Risk Rating

Comments


1 Machinery Hazard Flying objects like metal cuttings during machining operation, Impact injuries from equipment movements during Mobile Crane Operation for Maintenance& Repair works of HEMM

5 5 3 75 Medium

2 Chemical Hazard Exposure to Fumes, gases and ultra-violet light during Arc Welding, Exposure to Gas during Gas cutting

5 5 3 75 Medium

3 Fire Hazard, Burn & Scald Hazard

Risk of catching fire during Gas cutting, Explosion of DA Oxygen Cylinder during Gas cutting, Exposure to Hot water during opening of Radiator Cap, Exposure to hot zones during change of filter elements

5 5 3 75 Medium

4 Gravity Hazard Risk of falling objects/parts during EOT Crane operation for Maintenance& Repair works of HEMM, Fall by getting hit from moving objects during working near Rotating/ Moving Parts, Injuries due to slipping/falling on Shop floor during handling of used/burnt Lubricating oils

0.3 5 7 10.5 Low

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Hazard identification as regards to : Running/ rotating machines (H 9)

Haz. No..



1 Running machines, Rotating drives, gears, belts and couplings

Improper guarding and barricades 1 10 7 70 Medium

Inadvertent starting or operating the machine

1 10 7 70 Medium

Malfunctioning of operation controls 1 10 7 70 Medium

Working in close proximity 1 10 7 70 Medium

Lack of knowledge and skill 1 10 3 30 Medium

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Table-11 : Risk Control Plan

Risk Control Plan : Operation of dredge and upgradation unit (H 1)

Haz. No..

Sub-category of Hazard

Mechanisms Control Procedure ERCI (Existing

Risk Control Index)

Responsibility Comments

1 Fall or Slip of person to Pond Water

While walking on pontoons Provision of hand rails, chains, pontoon footboard flaps, Avoiding walking on pontoons during movement of the dredger

High Asst. Manager, Engineer

2 Electric shock While working with over head EOT crane, electrical maintenance of panels, transformers

Use of PPEs, Electrical isolation of machines before carrying out maintenance


3 Fall of person from height

While cleaning cutter, spirals, spiral distributors, while carrying out maintenance near trommel area

Use of boat and maintenance barge, Provision of hand rails, provision of ladder


4 Slip due to oil spillage

While doing maintenance of dredge pump, hydraulic machines, winches

Cleaning of deck floor High Asst. Manager, Engineer

5 Fall of materials from height

While handling pumps, motors etc. by chain pulley

Condition monitoring of chain pulley, use of chain pulley and sling of rated capacity


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Risk Control Plan : Fire (H 2)

Haz. No..



Risk Control Index)


1 General Fire Presence of inflammable material, static electricity, thunderstorm, electronic items

Ensuring compliance to all conditions permitted, Ensuring proper earthing of equipments, Regular checking of resistance of lightning arrestor, Not to use vehicles in case of leakages, Ensuring proper housekeeping, Avoiding storage of inflammable materials, Periodic replacement of gas pipes and regulators, Ensuring fire alarm, gas alarm and fire hydrant at critical locations, Ensuring flash back arrestor at both ends of welding gas lines, Using rectifier type welding machines, Conducting shop floor training on safety aspects and fire fighting, Conducting internal audits and safety visits, Conducting regular mock drills to ensure preparedness, Ensuring regular checking of electrical safety devices, Ensuring fire extinguishers at al critical locations and periodical checking of the same.

High Concerned Sectional Heads

2 Electrical Fire Electrical short circuits or malfunction of safety devices

High

Poor maintenance and inspection High

3 Fire in HEMM Electrical short circuits or malfunction High


4 Fire in buildings/ stores/ inflammable material storage

Electrical short circuits or malfunction High

Poor maintenance, inspection and improper storage

High

5 Fire/ explosion of diesel dispensing pumps

Deviation from permitted conditions High


High

6 Fire/ explosion of industrial gas cylinders

Lack of knowledge and skill High

Electrical short circuits or malfunction High



High

30

Risk Control Plan : Loading & Transportation of mineral (H 3)

Haz. No..



Risk Control Index)


1 Accidents while reversing of vehicles

Absent-mindedness of workmen, Failure of audio-visual alarm, Accidental hits to workmen/equipment nearby while reversing

Proper maintenance of AVAs of all HEMM is ensured; Entry of un-authorized persons in mine working is prohibited; Vigilant supervision at faces is ensured, so as to reduce congestion at faces. No provision of spotters/helpers near the machine; No person to be allowed to remain within the working radius of any equipment under operation.


2 Toppling of machine

During working at face, Speedy movements especially along wet roads, Sudden failure of brakes, Steering failure

Speed limits are maintained, Proper maintenance is ensured with vigilant checks to brakes, steering & suspension prior to release of vehicle for operation, To ensure proper levelling of loading platform; Operator shall prepare suitable embankments at face edges prior to loading of trucks.


3 Equipment collisions

Close movements at mine faces and haul roads – especially during overtaking situations, Sudden failure of brakes, Lack of visibility during monsoon period, Wet conditions with water accumulations on roads & faces

Speed limits are maintained, Overtaking is avoided; Minimum gap between moving dumpers in same direction is maintained. Proper maintenance is ensured with regular checks to brakes, steering & suspension prior to release of vehicle for operation. Use of Mobile phones during equipment operation is strictly avoided.


4 Exposure to Dust Dust generated during working in dry faces & haul roads

Adequate Water Sprinkling is ensured during working; Requisite PPEs are supplied to employees and are to be used by employees exposed to dusty environment.

Medium Asst. Manager, Engineer

5 Exposure to Noise Noise generated during operations

It is ensured that the machine has good cab enclosure; It is ensured that operators keep cabin doors closed during equipment operation.


31

Risk Control Plan : Electrical Maintenance (H 4)

Haz. No..



Risk Control Index)


1 Fall Hazard Fall of persons from height during 11 kV line maintenance, maintenance of lighting towers

Use of PPEs (safety net, safety belt etc.) is strictly ensured; Prior to works height permit is issued; Before commencement of any working at height, the respective area-In charge ensures that the persons engaged for the work is medically fit to work at height & have been imparted suitable training for safe working at heights., Work Instructions have been issued.


2 Electrocution Electric shock during operation & maintenance of transformer, DG sets, Sub-stations, motors

Use of PPEs (Safety shoe, hand gloves) is strictly ensured; Prior to works Shutdown permit is issued; Use of rubber mats, safety interlocks, earth leakage & other protection relays, Earthing system measurements are ensured. Works are undertaken under supervisors / competent workmen; Adequate lighting is ensured at the work site.


32

Risk Control Plan : Working at height (H 5)

Haz. No..



Risk Control Index)


1 Fall of person from height

While going up or getting down from height

Use of PPEs, safety belt, Provision of ladder, Provision of safety net, Training of personnel


2 Fall of object from height

While fixing sheets or executing painting work

Use of PPEs, safety belt, Training of personnel High Asst. Manager, Engineer

Risk Control Plan : HEMM Operation (H 6)

Haz. No..



Risk Control Index)


1 Hitting by loader Accidental collisions during operating/ maneuverings

Spotters/Helpers are not allowed near the machine; Entry of un-authorized persons is strictly prohibited.


2 Toppling of loader Working at slopes or face edges

Only Skilled & Experienced Operators are allotted for operation; Proper Vocational training is imparted to Operators; Necessary care is taken while working on slopes.


3 Exposure to Dust Dust generated during operation

Adequate Water Spraying on road; All requisite PPEs are supplied & ensured that those are used by employees.


4 Exposure to Noise Noise generated during operation

It is ensured that the sound levels do not exceed above permissible limit with periodical checks; Proper Maintenance is ensured.


33

Risk Control Plan : Structural Failure (H 7)

Haz. No..



Risk Control Index)


1

Failure of plant structure

Failure of plant structure

Structural stability test of critical installations, Visual inspection of structures for corrosion, wear and tear, Testing of lifting tools and tackles

Medium Concerned Departmental

Heads and Sectional Heads

2 Failure of structures of office building

Failure of structures of office building

Medium

3 Failure of overhead structures/ facilities (EOT cranes, etc.)


Medium

34

Risk Control Plan : Maintenance of HEMM (H 8)

Haz. No..



Risk Control Index)


1 Machinery Hazard

Flying objects like metal cuttings during machining operation, Impact injuries from equipment movements during Mobile Crane Operation for Maintenance & Repair works of HEMM

Appropriate signage are put at the site; Proper training is provided to workmen; Use of proper PPEs is strictly ensured.

Medium In-charge HEMM

and Workshop Supervisor

2 Chemical Hazard Exposure to Fumes, gases and ultra-violet light during Arc Welding, Exposure to Gas during Gas cutting

Medium

3 Fire Hazard, Burn & Scald Hazard

Risk of catching fire during Gas cutting, Explosion of DA Oxygen Cylinder during Gas cutting, Exposure to Hot water during opening of Radiator Cap, Exposure to hot zones during change of filter elements

Medium

4 Gravity Hazard Risk of falling objects/parts during EOT Crane operation for Maintenance& Repair works of HEMM, Falling by getting hit from moving objects during working near Rotating/ Moving Parts, Injuries due to slipping/falling on Shop floor during handling of used/burnt Lubricating oils

Low

35

Risk Control Plan : Running/ rotating machines (H 9)

Haz. No..


Mechanisms Control ERCI (Existing

Risk Control Index)


1 Running machines, Rotating drives, gears, belts and couplings

Improper guarding and barricades Ensuring guards, Ensuring zero direct access of persons to all rotating or running parts, No working without isolation of machines, Ensuring working by authorized persons only, Regular testing of electrical safety devices, Ensuring ergonomic and efficient systems for operation and local inspections.

Medium Concerned Departmental

Heads and Sectional Heads

Inadvertent starting or operation Medium

Malfunctioning of operation controls Medium

Working in close proximity Medium

Lack of knowledge and skill Medium

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CHAVARA ILMENITE MINE & VELLANATHURUTHU ILMENITE...

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