Welcome to Chairpersons & Participants

Transcription

1 Welcome to Chairpersons & Participants Safety Symposium & Exposition 215 Proactive Approaches towards Safety at Workplace & Beyond Jharia Division 1

2 Proactive approach towards Safety in Coal Mines Mr. Sanjay Kumar Singh General Manager, Jharia Division, Tata Steel Ltd Jharia Division 2

3 Tata Group - A Heritage of Sustainability Thoughts and Practices 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. Jamsetji Tata ( ) 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. Jharia Division 3

4 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

5 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

6 A Global Steel Company Tata Steel Group Ranked 11 th (year 214) in World in global steel production. Tata Steel India NatSteel Tata Steel Thailand Tata Steel Europe Revenue (FY15): TATA Steel Group: ~Rs.1,4, cr. ($ 25bn.) Product Segments Western Europe NML, Canada (iron ore) North America Latin America Western Africa Scandinavia Turkey Ivory Coast (iron ore) CEE India Oman (limestone) Mozambique South Africa (coal) China Orissa SE Asia Steel making operations Distribution and Commercial Centres including downstream assets Mining assets & projects Present in developed and developing markets across a wide range of segments Jharia Division 6

7 Tata Steel Operations 7 Purchased coal Raw Material Coke Sinter Iron Steel Making Own Coal Own Iron Ore Manganese, Dolomite 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 Finance & Accounts Human Resource Engg. Project Shared Services Corp. Functions Customers Marketing and Sales Jharia Division 7

8 Tata Steel India- Coal Mining Operation 6. MTPA Raw Coal Production Open Cast Mining Operations 1 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 5 m. Hydraulic Stowing with sand. Clean Coal is despatch to Jamshedpur after washing of Raw Coal. Jharia Division 8

9 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

10 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

11 Firedamp and Coal Dust Inundations Mine Fires Rock Bursts and Bumps Collapse of Pillars Side Fall Roof Fall Air Blast Blasting No. of person No. of disaster History of mining disasters in India since No. of person Killed No. of disaster disasters killing 144 persons from 2 to 214: 3 inundations 2 fire & explosion 2 ground failure Jharia Division 11

12 Death Rate Safety Statistics- Indian Mining Industry TREND IN DEATH RATE PER 1 PERSONS EMPLOYED Coal mines Non-coal mines Decade Jharia Division 12

13 Production & Manpower trend- Coal Mining Output in ' tons 6 Trend in production of coal- Placewise 5 U/G Opencast Year Jharia Division 13

14 Manpower in Production & Manpower trend- Coal Mining Manpower trend in coal mines- Opencast & Under ground 35 3 U/G O/C Year Jharia Division 14

15 Current Safety Scenario Coal mining contributes around 7% 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 214. In opencast operation, mostly accidents are caused due to HEMM operation (39.29%). Jharia Division 15

16 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

17 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 No of Accidents Safety Excellence Journey at Jharia Division 1 Fatal Accident at Jharia Division and Raw Material Division of TATA Steel Raw Materials Division Jharia 4 3 FY5 FY6 FY7 FY8 FY9 FY1 Safety Excellence Journey Launched 1 2 Jharia Division 18

19 Nos.of Accidents Face employe es Support employe es Supervis ors Within 1 Mtr 1-5 Mtrs More than 5 Mtrs Cum % Nos of Accidents. Cum % Fall of Roof & Side Fall of persons Rope haulage / Tob movement Hit by Objects Inrush of Water Others Nos. Cum % Data analysis of Accidents in Jharia (since 1999-FY1) Cause wise analysis of Fatal and Serious Accidents Conclusion: Fall of Roof & Side accounts for more than 68 % of total accidents. Cause of accident Analysis of Accidents due to Roof & Side Falls Employee type wise Working Place wise Conclusion: Employees within 1 Meters of the working face are more vulnerable to accidents. Jharia Division 19

20 Cause & Effect for Fall of Roof & Sides within 1 Meters. Jharia Division 2

21 No of Accidents Cumulative % Cause & Effect for Fall of Roof & Sides within 1 Meters. Data Analysis of Main Causes for accidents roof & side fall within 1 meters from the working front Nos Cumm % Improper Roof Support 2 1 Inadequate Side Unsupported Roof Support Causes for Accidents 25 89% Vital Few was considered for Action Jharia Division 21

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 3 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 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 3 Meters. Jharia Division 22

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 3 meters. a.fail Safe Jharia Division 23

24 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

25 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 Replaced 1.9m roof bolts by 2.4 metres Reduction in damage of immediate strata. Strata Control System Replaced cement capsule by Resin Capsule Introduced Cable bolting of 5 metres long Introduced Strata Condition monitoring instrumentation (Load cell, Tale tell & convergence recorder) Increase in load bearing capacity up to 1 ton and better strength in watery condition Increase in percentage of extraction in depillaring. Auto Warn: Introduced first time in India, and is a visual warning system. It gives early warning before strata failure. Load cell, Tale tell Jharia Division 26

27 Key Issue and Action Taken- Human Interface Area Key Initiatives and efforts In- Process Effects 8 Nos of LHDs to replace 16 Nos of SDLs Reduction in manpower exposure to mining hazards. Improving Mechaniz ation Manual drilling practice has been completely replaced by roof bolting machine 4 Nos of UDM have been deployed for drilling To eliminate blasting, one Road Header has introduced in phase wise. Tub mining has been replaced with belt conveyor at one unit Reduction in fatigue of persons due to manual drilling in roof Exposure of person at face is completely eliminated Damage of strata due to blasting is eliminated Hazard of tub mining eliminated UDM Road header LHD BEFORE : Manual Drilling of Holes for roof bolting AFTER: Mechanized Drilling of Hole Jharia Division LHD- Load Haul Dumper, SDL- Side Discharge Loader, UDM- Universal Drill Machine 27

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 Use of higher capacity auxiliary fans of 6 cum/min started for better ventilation 6 Nos of staple pits have been made at Sijua, Digwadih & 6&7 Pits Colliery Old MMV of 5 cum/min capacity have been replaced with new MMV of 8 cum/min capacity at Sijua Colliery Reduction in fatigue due to arduous traveling Quantity of air at face increased resulted in reduction in face temperature from 34º to 31º C Resistance in ventilation circuit reduced resulted in increased in quantity of air Total air quantity at Sijua improved by 5 % Hand Rail Man riding 6 Cum Auxiliary Fan Jharia Division MMV- Main Mechanical Ventilator 28

29 Fatal Accidents Journey on Safety at Jharia FATAL ACCIDENT RMD & JHARIA Based on past years analysis : 6% of Fatal Accident cause due to Roof / Side Fall in Underground near working Face Roof / Side Support Design of Roof Bolt Use of resin capsule Scientific Study (RMR) FY5 FY6 FY7 FY8 FY9 FY1 FY11 Raw Materials Division Jharia In spite of action taken in FY1 to arrest roof fall/side fall there were accident in FY11. Jharia Division 29

30 FY11 Fatal Accident analysis Main Cause of Fatal Accident in FY-11 Electrocution Drowning By stowing water Crossing Belt Conveyor SDL running without canopy 1 SOP not followed Process Failure SOP not followed SOP not followed Fatal Accident Process Failure SOP Not Followed Behavior al Issue In FY1 behavioral issues were not addressed which cause accident in FY11. In FY 11 more focus on behavioral issues Jharia Division 3

31 Enhance Safety Excellence Journey 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) Jharia Division 31

32 Mechaniza tion Fail Safe & Fool proofing Behavioral Enhance Safety Excellence Journey Additional New Safety KPIs for Enhance Safety Excellence Journey SL Action Type Safety KPIs Unit of Measure 1 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 5 Mass meetings chaired by senior management Nos. 6 Monthly Campaign on Safety Nos. 7 Safety Drama at Pit top and colonies Nos. 7 CAUPs identified & Mitigated Nos. 8 FRCPs identified & rectified Nos. 9 FRCPs identified related to unsafe acts Nos. 1 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 Nos. 14 Employees removed from hazardous place through mechanization No. of employees 15 Safety schemes proposed Nos. New KPIs Added for DIC Review Jharia Division 32

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 CAUPs mitigated Nos Employees identified violating life saving rule and disciplined No. of employees Employees identified violating safety rules and disciplined No. of employees FRCPs identified Nos FRCPs rectified Nos FRCPs identified related to unsafe acts Nos SOPs developed with visuals Nos SOPs revised as per JCC Nos Employees trained on positive isolation No. of employees 1 % 1% Jharia Division 33

34 Status of main KPIs of ESEJ (contd..) S. No. KPI UOM Mar 11 Apr 11 to Mar 12 Plan Actual Plan Actual Remarks 11 Employees trained to improve skill No. of employees Safety programs conducted for house wives Safety programs conducted involving school children Nos Nos Mass meetings chaired by GM Nos Employees removed from hazardous place through mechanization No. of employees Safety schemes proposed Nos Jharia Division 34

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36 Changing behavior: Messaging through School children and Family Safety awareness Program conducted involving school children Jharia Division 36

37 Enhance Safety Excellence Journey Revised safety organizational structure Apex safety Council Meeting, Chaired By MD DIC(RM) Chaired By VP DIC(JH) Chaired By GM Training and Communi cation sub Committe e 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 Head Safety Changes in safety organizational structure Safety Officers Jharia Division 37

38 Changing behavior: Life Style management program Rolling our Anemia Control Program Awareness Program on Anemia Control JAGRAN Program JAGRAN Program 38 Jharia Division 38

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 Joint Mass Communication are being organized along with Union on regular basis Incident based communication films Safety through community (Khushali, SAFE CLUB) Sumilan Program was organized for contractors Safe act index improved from 65% to 74% Employees participation in safety improved Learning from past incidents to prevent reoccurance of such incidents To inculcate safety culture among school children, community and family members Contractors safety competency development CP R Jharia Division 39

40 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

41 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 LTIFR - Jharia Effect Fatal Analysis Trend Safety Excellence journey Enhanced Safety Excellence journey FY5 FY6 FY7 FY8 FY9 FY1 FY11 FY12 FY13 FY14 FY LTIFR Trend (FY7-FY15) 4.18 Plan Actual FY7 FY8 FY9 FY1 FY11 FY12 FY13 FY14 FY15 Jharia Division LTIFR- Loss Time Injury Frequency Rate 42

43 Key Achievements in Safety in Fy 15 Greentech Safety award 215 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. Jharia Division

44 Key Achievements in Safety in Fy 15 Jharia Division Rescue team won 2 nd Prize in 45 th All India Mines rescue competition held at MRS Ramgarh 6 & 7 Pits Bhutgoria Amalgamated Colliery won overall prize Sijua Colliery won 1 st Runner s up prize Achievements in Annual Mines Safety Week In Annual Mines Safety Week 214 Jharia Division won total 29 prized in various categories. Tata Central Hospital Jamadoba won best occupational health center. In Annual Mines Safety Week 214 Jharia Division won total 29 prized in various categories. Jharia Division 44

45 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

46 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

47 Future Mechanization Plan Improving Working Condition 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 Jharia Division 47

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50 Fatal Accidents Rate Overall Effects Plan Actual Behavioral Safety Managemen t Process Safety & Job Cycle Check OHSAS SEZ with DuPont FY5 FY6 FY7 FY8 FY9 FY1 FY11 FY12 LOSS TIME INJURY FREQUENCY RATE JHARIA RMD Jharia FY5 FY6 FY7 FY8 FY9 FY1 FY11 FY12 FATAL ACCIDENT RMD & JHARIA Zero Fatality Jharia Division 5

51 LTIFR - Jharia Roof Fall Tub Movement Drowing in stowing incline Fall in stowing lift SDL running without canopy Drowing at Face Crossing over belt Not following Positive Isolation Poor Housekeep ing Analysis of accidents at Jharia FY5 FY6 FY7 FY8 FY9 FY1 FY11 FY12 FY13 FY14 FY Fatal Analysis Trend Cause Wise Fatality LTIFR Trend (FY7-FY15) Plan Actual FY7 FY8 FY9 FY1 FY11 FY12 FY13 FY14 FY15 14% 16% 8% All Incidences FY 15 21% 27% 1% Hit by Object Fall of Object Slip of Person Fall of Person Roof Fall Side Fall Others 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 Jharia Division LTIFR- Loss Time Injury Frequency Rate 51

52 Jharia Division 52