Welcome to Chairpersons & Participants · Welcome to Chairpersons & Participants ... Mr. Sanjay...

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

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






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






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






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


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


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


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


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


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






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






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

Welcome to Chairpersons & Participants · Welcome to Chairpersons & Participants ... Mr. Sanjay...

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