International Vision Zero Conference on OSH 15 th - 17 th March-2017 Vigyan Bhawan - New Delhi
The Singareni Collieries Company Limited (A Government Company) Deep Underground Mine Environmental Issues A case study for Improving Safety & Health of Employees in SCCL N Sridhar, IAS, Chairman & Managing Director A Manohar Rao, Director (Planning & Projects) K Sugunakar Reddy, Chief General Manager K Guruvaiah, General Manager
The outline Introduction of SCCL. Safety & Health of employees Issues of deep underground mining. Improvement of environmental conditions Conclusions
Pranhita-Godavari Valley Coal Field 4
History of SCCL Dr. William King of GSI discovered coal deposits near Yellandu in Khammam district in 1871. The Hyderabad (Deccan) Company Limited incorporated in England acquired mining rights in 1886. Mining coal since 1889. Christened as The Singareni Collieries Co. Ltd. on 23 rd December, 1920. Since 1945 it became a Government company as The Nizam of Hyderabad acquired the shares. From 1960, the GoI has become equity partner along with GoAP. Sir William King CHP - 1928 Power Plant 1928 5
Naini coal block LOCATION & EXTENT 1 2 3 4 SCCL Godavari Valley Coal Field Stretched over a length of 350 Km along 6 Districts of Telangana State 5 6 1. Kumram Bheem, 2. Mancherial, 3. Peddapalli, 4. Jaya Shankar, 5. Bhadradri & 6. Khammam District
SCCL at a glance. SCCL is contributing 9.5 % in the all India domestic production Presently, operating 47 Mines: 30 Underground & 17 Opencast Spread in 6 districts of Telangana State Manpower as on 31.01.2017 : 56,658 Proved coal reserves is 10,128 MT (as on 01.04.2016) Since inception (1889) extracted 1,280 MT coal Produced 60.38 MT coal and Excavated 311 MCM of OB during 2015-16 Operating captive power plant, recently commissioned 2x 600MW capacity thermal power plant 7
Performance last 5 years Indicators Unit 2011-12 2012-13 2013-14 2014-15 2015-16 Production Off-take Million Tonnes Million Tonnes 52.21 53.19 50.47 52.54 60.38 51.51 53.34 47.94 52.73 58.68 OB Removal Million Cu. M 209.73 175.84 168.78 262.82 310.98 OMS Tonnes 3.94 3.94 3.84 4.20 4.73 8
Introduction SCCL has been pioneer in mechanization: 1937 Coal Drill Machines 1950 Shuttle Cars, Gathering Arm Loaders, Conveyors and Coal Plough 1975 Shovels and Dumpers 1979 Side Discharge Loaders 1981 Road headers & Load Haul Dumpers 1983 Long-wall 1986 Dragline 1989 Blasting Gallery 1994 In-pit crushing and conveying 2002 Surface Miner 2006 Continuous Miners 2010 High-wall Mining 2014 High Capacity Long-wall (2.817 mtpa)
SCCL Technology-wise Production (LT) 700 600 500 400 300 200 100 0 73-74 74-75 78-79 80-81 84-85 85-86 89-90 92-93 96-97 97-98 20 01-02 20 02-03 20 06-07 20 07-08 20 08-09 20 09-10 20 10-11 20 11-12 20 12-13 20 13-14 20 14-15 20 15-16 Hand Section Machine Mining Longwall Opencast 10
Challenges specific to SCCL Geology :- Not feasible for L/W mining. Clay bands in coal seams: challenges of strata management. Poor Quality of coal limiting investments. Economical considerations in introduction of belt conveyors. Aging work force:76% of around 58,000 employees strength. Steep gradient of seams 14-23 degrees.
Steps taken for improvement. Phasing out the manual loading by LHD s & SDL s. Continuous Miner Technology in feasible areas. Blasting Gallery method for extraction of thick seams. Long-wall technology was for bulk production. Roof bolting by mechanical bolters with Resin. Men transport systems in U/G mines to reduce fatigue and haulage safety (Chair lift systems, Rail car systems and diesel operated mine cruisers).
Steps taken for improvement. Higher Capacity open cast mines. HEMM to reduce the fleet in Inert gas systems (N 2 & CO 2 ) for prevent heating Air-cooling systems in needy mines to improve workplace environment. Involving national and global Scientific and Academic institutions like CIMFR, NIRM, ISM, IIT's, NIT's, and CSIRO in design and planning. Training by global institutions to enhance SMP. World class Rescue services to reduce losses.
Safety status AVERAGE (5 YEARS )TREND OF FATAL ACCIDENTS IN SCCL PERIOD ACCIDENTS RATE/MILLION TONNE RATE/3 LAKH MANSHIFTS RATE/1000 MEN ON ROLL FA F F F F 1991-1995 25 30 1.27 0.34 0.28 1996-2000 29 32 1.10 0.39 0.32 2001-2005 16 24 0.74 0.33 0.26 2006-2010 7 9 0.34 0.28 0.23 2011-2015 9 5 0.16 0.18 0.17 FA=Fatal accidents; F=Fatalities;
Safety status CAUSE-WISE -MAJOR CONTRIBUTORY FATAL ACCIDENTS IN SCCL FOR FIVE YEARS. CAUSE 1991-1995 1996-2000 2001-2005 2006-2010 2011-2015 ROOF FALL 69 49 45 20 9 SIDE FALL 12 20 11 7 5 ROPE HAULAGE 28 26 17 13 1
Health status AVG. NATURAL DEATHS WHILE ON DUTY IN SCCL YEAR AVG. NO. OF NATURAL DEATHS PER YEAR 2002-2005 12 2006-2010 11 2011-2015 11
80 70 FATAL ACCIDNETS TREND 69 SINCE 1991. 60 50 40 49 45 30 20 10 0 28 26 12 20 20 17 11 13 7 9 5 1 1991-1995 1996-2000 2001-2005 2006-2010 2011-2015 ROOF FALL ROPE HAULAGE SIDE FALL
Future plans on S & H Implementation of of the employees. health monitoring data base Introduction of slope monitoring radar in deep O/C mines. Planning for introduction of bulk production technologies. Up grading the employees skills by improved training methods. Quality PPE s to prevent injuries to phalanges.
Issues of deep underground mining Deep U/G mining will have the additional challenges such as difficult geo-mining and adverse environmental conditions. Current operating depth and extent of U/G mines in SCCL is 400-550m & 4.0-8.0 km. Planned for 720m depth in near future. Envisaged for 1200m. Shift to high production technologies like Continuous Miners & Long-wall.
Issues of deep underground mining Heavy mechanization with face machines up to 8MW and large network of conveying systems up to 10MW installed power. High capacity machines, geo-mining conditions and faster extraction add substantial heat to working environment apart from heavy inrush of inflammable gases, hot water and dust. Majority of heat load to mine air in deep mines is due to rock temperature, machinery and mine water.
Issues of deep underground mining In SCCL, VRT is about 42.5 0 C at 720m depth. Comfortable and productive mining requires optimum temperature below 28.0 0 C. Comfort at workplace requires substantial increase of air flow rate by eliminating heat sources or separating ventilation. Limitations to improve comfort by increasing air flow rate requires to adopt artificial cooling arrangements of mine air.
Mines with high mechanization. VK. No.7 Incline Continuous Miner 4.0 LPTA 2006 GDK. No.11 Incline Continuous Miner 4.0 LPTA 2008 Adriyala Longwall Project Longwall 28.17 LPTA 2014
Improvement of environmental conditions VK. No.7 Incline: Main Mechanical Ventilators : 225kW, 120m 3 /s 150kW, 60m 3 /s Air-cooling System (u/g) : 500 RT (to reduce temp. of 50m 3 /s air quantity from 33 0 C to 25 0 C in Continuous Miner workings) N 2 Generator : 800m 3 /h Cryogenic CO 2 Storage : 30 tones
Chillers location Continuous Miner workings
WATER COOLED CHILLER UNIT OF UNDERGROUND AIR COOLING SYSTEM INSTALLED AT VK No.7 INCLINE
Schematic lay out of the Air-cooling System Make up water P E C C Condenser Water P RG OC-II W ALP Entries from Highwall Chilled Water Mine Airway AHU C: Chiller Compressor/Condenser E: Evaporator P: Pumps AHU: Air Handling Unit
Improvement of environmental conditions GDK. No.11 Incline: Main Mechanical Ventilators : 2 x 225kW (parallel operation) 280m 3 /s Air flow in Continuous Miner workings is 75-85m 3 /s to maintain work place comfort and to dilute the exhaust gases of diesel powered Ram-cars. N 2 Generator : 800m 3 /h Cryogenic CO 2 Storage : 30 tones
Improvement of environmental conditions Adriyala Longwall Project: Main Mechanical Ventilator : 400kW, 180m 3 /s Air-cooling System (surface) : 1200 RT (to reduce temp. of 50m 3 /s air quantity 9.0 0 C at surface to have temp. less than 28.0 0 C in Long wall face) N 2 Generator : 1800m 3 /h Cryogenic CO 2 Storage : 30 tones.
VENTILATION PLAN OF ADRIYALA LONGWALL PROJECT ALP Entries from Highwall
Ventilation network model of Adriyala Longwall Project RG OC-II ALP Entries from Highwall
VENTILATION SCHEMATIC OF ADRIYALA LONGWALL PROJECT Punch Entries 185 m 3 /s UC PE-5 185 m 3 /s 130mmwg 400kW Fan ALP Entries from Highwall 50 m 3 /s TG-1 70 m 3 /s MG-1 BF TG-2 Energy Centre 20 m 3 /s 50 m 3 /s LW FACE Control Centre 45 m 3 /s RH-1 MG-2 TG-3 BF 45 m 3 /s 40 m 3 /s BF: Booster Fan RH: Roadheader RH-2 Poty 15 m 3 /s
Air-cooled Chillers installed at Adriyala Longwall Project
Air Handling Units installed at Adriyala Longwall Project
Ducts discharging chilled air in one of the entries at Adriyala Longwall Project
Conclusions In deep U/G mining, Planning and introduction of bulk production technologies is mandatory to increase safety, productivity and economy. High mechanization at greater depths have difficult geo-mining conditions, ambient environmental issues etc... Increasing capacity of mine ventilation systems & introduction of Air-cooling systems, inert mechanisms to improve work place env. Conditions for safety and economics. Improving work place environment also enhances the health of employees.
Authors are very much thankful to the management of the SCCL for permitting to publish this paper and to use certain data for presenting in this paper SCCL is thankful to: The Ministry of Labour & Employment (GoI), DGMS, and Directorate General Factory Advice Service & Labour Institutes. DGUV (German Social Accident Insurance) issa (International Social Security Association)
Thank you