1. Mining Safety: Challenges and Opportunities WELCOME TO ALL ATTENDEES IN THE HALL FOR AN ADDRESS ON Dinesh Srivastava Jayaswal Neco Industries Ltd

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3. Sarve bhadrani pashyantu, ma kascit dukha bhaga bhavet May all be happy, may all be free from disease May all have well-being and none have misery of any kind. [Brihadaaranyaka Upanishad 1.4.14 ] ॐ सर्वे भवन्तु सुखिनः सर्वे सन्तु निरामयाः । सर्वे भद्राणि पश्यन्तु मा कश्चिद्दुःखभाग्भवेत् । ॐ शान्तिः शान्तिः शान्तिः ॥

4. Earliest Pre-Harappan Mining History. Modern Mining era of Coal extraction started in 1774. Only seven minerals were mined in the beginning of 20 th Century. Political Independence provided real boost to the growth of mining. 22 Minerals were mined in 1950 valued at Rs. 70 cr.

5. 84 major, 23 minor & 3 atomic minerals are mined now. Rs 2.10 lakh Cr worth value of minerals produced in 2011-12 Accounts for 2.6% of the country’s GDP Accounts for 68.22% fuel minerals, 11.94% metallic,11.85% non-metallic including minor minerals at a total value of mineral production

6. India’s share to world’s Mineral Prod 1 st in Mica. 2 nd in Chromite. 3 rd in Coal & Lignite. 4 th in Iron Ore. 6 th in Bauxite. 8 th in Manganese Ore. 10 th in Al 11 th in crude steel. 4 th in mineral prod in world

7. INTRODUCTION History of mining in India is marred with sporadic occurrence of accidents involving a large number of fatalities. Despite rapid advancement in technology and management, accidents in mines due to fall of roof and sides, rope haulages, wheeled trackless transportation machinery, fire, explosion, inundation, etc have been occurring now and then.

8. - The condition of being protected from or unlikely to cause danger, risk, or injury: "they should leave for their own safety". -Denoting something designed to prevent injury or damage: "a safety barrier"; "a safety helmet". What does safety mean ?

9. Accident ? Conventionally, any mishap in which one or more persons are killed or injured constitutes an accident. Accident may be defined as an unexpected event causing loss of life or bodily injury The Mines Act does not define an accident. Section 23 is simply titled as Notice to be given of accidents, but makes no attempt to define an accident.

10. ACCIDENT Individual Environment System & equipment Three elements of causation of accident

11. A tablet found in Portugal describes what must be the first Support rules: “The roof is to be supported by leaving pillars or the use of props. It is forbidden to damage the pillars or remove the prop. In 1510 Agricola advised on support and ventilation, the main concern being safety rather than profit

12. Till about 1930 it was believed that physical conditions were the cause of most of the accidents. Therefore corrective action was taken which showed good results. There was substantial reduction in the number of accidents

13. But In 1931 HW Heinrich propounded a theory that unsafe acts of people cause more accidents than unsafe conditions He analyzed a large number of accidents and concluded that 98% of accidents were caused by hazardous conditions or dangerous acts and these could be prevented.

14. Only 2% of the accidents were caused by the act of nature or GOD and were unpreventable. Out of 98% of preventable accidents 88% were caused by unsafe acts of men and only 10 % were due to unsafe physical or mechanical conditions

15. The unsafe acts of men and unsafe mechanical and physical conditions is demonstrated by game of Domino and is demonstrated by oblong pieces of wood called dominoes. These are placed in a row in a manner that the fall of the first causes the fall of the entire row. But if any of the middle dominoes are removed the series is interrupted.

16. Ancestry school environment Fall of person Unsafe act/condition Accident Injury The Five Factors in accident sequence Dominoes sequence 123 45

17. Injury is caused by the action of preceding factors Dominoes sequence

18. Removal of the central factor makes the action of preceding factor in effective Dominoes sequence

19. Five factors in injury sequence: Ancestry and social environment (undesirable traits of characters inherited/acquired from social environment) Fault of person (undesirable traits lead to faults of person) Unsafe act and/or physical or mechanical hazards (fault of person is responsible for unsafe acts/ the existing hazard) Accident (unsafe acts/conditions lead to accident) Injury (accidents lead to injury)

20. Safety and mines Mine safety connotes the condition of being safe from hazards like: Which cause or could cause bodily injury This constitute mine accident Which are injurious to health This causes occupational hazards -Accidents can be recognized easily and immediately While occupational hazards develop slowly till worker is aware and loses bodily function

21. International experience shows that more people are killed or are disabled by occupational dieses of mining than accident YET THE ACCIDENTS IN MINES RECEIVE THE SPOT LIGHT OF CONCERN WHILE THE SILENT KILLER AND OTHER ACCIDENTS GO UNNOTICED

22. Nation wise road accidents in India are 390 per day In 2012 17 lives were lost/hour as against 15 live in 2010 1.42 lakh people died in 2011 1.34 lakh people died in 2010 1.26 lakh people died in 2009 1.20 lakh people died in 2008 1.14 lakh people died in 2007 Fatalities on Road

23. ACCIDENT IN MINES The term accident has been derived from the Latin word ‘Accidere’ which means ‘fall of an object’. Any falling object which causes damage to the men and machine is categorized as accident.

24. The Mines Act says: Whenever there occurs in or about a mine an accident causing loss of life or serious bodily injury, or an explosion, spontaneous heating, outbreak of fire, inrush of water or gas, premature collapse of any part of the workings, over-winding of cages, etc a notice has to be given immediately in the prescribed form to the prescribed authorities. (Even if there is no loss of life or injury, they are deemed to be accidents.)

25. Types of accidents Disaster: mine accidents having high risk and potential to inflict heavy fatality simultaneously damaging mining conditions and occurrence of 10 or more fatalities. Major accidents: involving fatalities more than 3 but less than 10 Fatal accidents': resulting in fatalities up to three persons

26. Serious: an accident describing ‘seriously bodily injury” means any injury which involves or in all probability will involve permanent loss of any part of body or injury to sight or hearing or any physical incapacity or the fracture. Reportable: means any injury other than a serious bodily injury which involves or in all possibility will involve the enforced absence of the injured for more than 72 hours. Minor: means a minor injury resulting in absence for more than 24 Hrs.

27. Measurement of safety Safety can not be quantified Absence of accident is no safety Accident statistics are the only yard stick to judge safety International practice to express accident rates is in relation to exposure i.e.: Death/injury rate on the basis of One million man hour worked One lakh man shifts worked One thousand person employed

28. In India the frequency rate is calculated on one lakh man shifts worked or 1000 persons employed To calculate frequency rate per mill of production is also sometimes adopted but it does not reflect the real trend

29. ACCIDENTS Fatal accidents in Coal mines (in India) in last 112 years (Since 1900) are 7933 no’s average coming to 181 per year Fatalities in China in coal mines in 20111973 20121384 Around 7000 deaths recorded a decade ago May 12 2013 – 40 fatalities in two mines May 11 2013 – 22 fatalities Mar 13 2013 – 21 fatalities Jan 30 2013 – 12 fatalities Nov 24 2012 – 17 fatalities Nov 12 2011 – 20 fatalities 20 trapped in a pit in Meghalaya since July 6

30. On an average 250 persons are killed in mine accidents every year. Out of these 180 are killed in coal and 70 are killed in metal mines. The number of persons receiving serious bodily injury is about 1100 per year. Out of these 800 are injured in coal and about 300 in metal mines. Place of accident Fatal accidentPersons killedSerious accident Seriously injured Under ground 84 (62%)122 (69%)463 (70%)503 (71%) Open Cast 29 (21%)30 (17%)70 (11%)75 (11%) Above ground 24 (17%)24 (14%)125 (19%)130 (18%) Total 100 Place wise analysis of accidents in coal mines

31. Three production/safety era in Indian coal history are considered important: Pre independence era 1900 to1950 Post dependence pre nationalization 1850 to 1970 Post nationalization era 1970 to till date

32. The relation ship between production and safety can be related in three eras Production and no or little safety Safety and little production Safety and production go together sharp decline in fatality rate over a period of 100 years: Drop in fatality rate from a peak of 1.29 per 1000 persons in 1911 to 1920 deployed to 0.22 in 2011-12 mainly because of: Share of u/g production dropped from 86.32% in 1951 to 9.35% in 2011-12 Share of o/c production increased from 13.68% in 1951 to 90.61% in 2011-12 At the time of nationalization heavy influx of person took place

33. No of fatalities in Indian Coal mines AV/YR 1901 to 1950 (50 yrs) 9880197.6 1951 to 1970 (20 yrs) 5550 277.5 1970 to 2012 (42 yrs) 7833186.5 Total 112 yrs23263207.7 Since last two years fatal accidents are all time low 112 in 2011,116 in 2012. Total no of accidents across coal, metal and oil mines has decreased more than half from 1358 in 2005 to 591 In 2012. T/mines- 566(Coal), -2500(metal), oil-29

34. There are 566 coal mines out of this 360 are u/g and 130 o/c while rest 76 are mixed mines Out of around 5 lakh of workers 20% are deployed in o/c producing 85% production while 80% worker deployed in u/g produce only 15% production This means more persons are exposed to danger in u/g.

36. It is generally perceived that o/c mines are safer than u/g. But if we calculate accident rate on mill ton and per mill man shift basis we fine this perception may not be true. Safety perception o/c vs u/g mines For the period between 1989 to 1997 (CIL) Based on production (mill t) accident rate is 1.236, 0.144, and 0.102 respectively for u/g, o/c and surface accidents. For a fixed amount of production accidents in u/g are 8.5 times more frequent than o/c.

37. Based on million man shift accident rate is 0.687, 0.579 and 0.160 respectively for u/g, o/c and surface. For fixed mill man shifts accidents in u/g and o/c are comparable. For pooled data of all companies in CIL for the period for all types of accident combined the rate is 0.526 based on mill ton is comparable to 0.822 if based on per million man shift. On mill ton basis NEC, BCCL, ECL and CCL are more accident prone On mill man shift basis BCCL, MCL and NEC are more accident prone

38. 199519961997199819992000 Fatal Accident in coal mines AKAKAKAKAKAK U/G 91173758894114809774846376 O/C26 2729272924 30313952 Serious Accident in O/C coal mines U/G549595478514440477346380408446434466 O/C6971 75798572737785104111 Trend in accidents (Six Years ) A- Accidents, K- Killed

39. YearAv No of Accidents Accident rate Av no of fatalities Fatality rates 1901-10740.77920.94 1911-201380.941761.29 1921-301740.992191.24 1931-401720.982281.33 1941-502360.872731.01 1951-602220.612950.82 1961-702020.482600.62 1971-801870.462640.55 1981-901620.301840.34 91-20001450.271700.33 FATAL ACCIDENTS AND FATALITIES Accident and death rates are per ‘000 persons deployed

40. YearNo of fatal accidents No KilledD.Rate/1000 persons D.Rate/Mill te 19512783190.919.3 19612222680.654.81 19711992310.603.05 19811651840.361.45 19911381430.260.60 20001171440.310.43 20011051410.320.41 200281970.230.27 2003831130.270.30 200487960.240.26 2005961170.29 2006791380.360.34 200777790.200.19 2008871000.250.24 Accident statistics 1951 to 2008 (58 years)

41. Causes of accidents Fatal Accidents (%)Serious Accidents (%) AccidentDeathsAccidentsInjuries Roof Fall43.641.912.514.9 Side Fall14.011.17.7 Other G/movement 0.81.40.20.8 Haulage17.013.025.724.3 Conveyors1.51.11.31.2 Transport m/c1.21.0 Other m/c2.31.72.2 Explosive4.03.61.83.1 Gas /dust/ fire1.73.50.1 Fall of person6.14.622.520.9 Fall of object1.71.315.714.6 Other causes6.115.89.39.2 All causes100 Cause wise analysis of accidents in u/g for 6 years

42. Cause of accident Fatal accidents (%)Serious accidents (%) AccidentsDeathsAccidentsInjured Fall of overhangs 5.29.41.11.0 Dumpers/trucks 54.953.427.629.6 HEMM 17.315.718.017.2 Fall of persons 3.53.127.526.0 Fall of object 3.53.711.010.6 Other causes 15.614.714.815.6 Total 100 Cause wise % of accidents in o/c for 6 years

43. Exp/FireInund ation Fall of roof/sides OthersAll cause 1991-25 (25 yrs)1022317 1926-47 (22 Yrs)521210 1948-73 (26 yrs)552012 1974-2K (27yrs)552012 2001-05 (05 yrs)03104 Cause wise period wise no of disaster

44. Inundation Exp/FireInuFall of roof/side OthersAll cause 1991-25 (25 yrs) 0.400.08 0.120.18 1926-47 (22 Yrs) 0.230.900.050.900.45 1948-73 (26 yrs) 0.19 0.080.000.46 1974-2K (27 yrs) 552012 2001-05 (05 yrs) 03104 Cause wise wise no of disaster per year

45. ACCIDENT COST TO EMPLOYER Medical Treatment Compensation Pension First Aid Loss of Production Plant Damage. TO EMPLOYEE Decreased Income Financial Loss attributable to decreased income. Loss of Earning Power Direct Costs

46. TO EMPLOYEE Personal Pain & mental concern Inability to enjoy normal relations Problem in family life Loss of morale Economic loss to the family Loss of time of fellow workmen TO EMPLOYER Loss of Employee’s skill Loss of production Accident Enquiries & Reports Labour unrest Damage to m/c Loss of time Spoiled job Breaking in new men Indirect cost

47. After analyzing every thing question is what do we do to reduce accidents? Fatal accident is worst form of accident as well occupational dieses so: We need to evolve a strategy at first hand to provide condition for Minimum accident potential (MAP) in a mine. And finally to map out to achieve Zero Accident Potential (ZAP). (This recommendation was made by Fourth conference of Mines safety held in Dec’1978)

48. Challenge Opportunity Challenges and opportunities are complementary and supplementary to each other Each follow the other Are two sides of the same coin Environment Challenges and opportunities

49. Challenge/Opportunities Since 88% accidents are due to act of men – it can be corrected by: (Correct men) Education Training Provide good living conditions Control of physical/mechanical hazards Strengthen VTC Use of protective wears* Follow safety rules Avoid unsafe act keep away from moving machine

50. “SAFETY IS MY RESPONDBILITY” nation wide campaign was launched on 4/5 July’2013 in the inaugural function of 11 th safety conference in mine. Each mine worker to carry a card containing 10 important questions reminding employees to ask before the start of work in mine. If no he should take up with his senior supervisor SAFETY IS MY RESPONSIBILITY

51. 1.Have I been adequately trained for the work or am I with an adequately trained supervisor. 2. Does a SOP exists for this work. 3. Do I have required knowledge about this work place. 4. Are the suitable tools and equipment provided and are they in good condition. 5. Do I have necessary PPE.

52. 6.Do I have required authorization/permit permission for the work. 7. Can whether working condition, work environment or poor lighting affect job safety. 8. Are there any danger created by my activities or am I in danger due to others activities. 9. Are work environment hazards to health. 10. In the event of emergency do I know the emergency plan.

53. To achieve ZAP it is important to ensure technological control of hazardous conditions which encompass four engineering aspect like: Design Construction Operation Maintenance These are mutually interdependent Good - design reduces the hazards Construction and operation -minimize maintenance Maintenance in turn -allows machines optimum quality of safe operation ZERO ACCIDENT POTENTIAL

54. Correct conditions Bring down the hazards by all means to an acceptable level. Improve ventilation/lighting Make Equipment less noisy Provide better amenities at site Maintain safety devices operative Maintain good house keeping Avoid defective/damaged/faulty design of equipment Maintain protective devices

55. In last two decades, coal mining has witnessed a phenomenal growth in production from 75mill Te in 1971-72 to 554 mill Te in 2011-12, 557.5 mill te in 2012-2013. Coal Vision 2025 estimates demand of coal for up to 2024-25 for the different sectors based on the forecast made by TERI considering the coal demand and the change in the GDP. The adopted approach indicates that the over all growth in coal demand Is expected to be 5.62% with 8% GDPand 5.04% with 7% GDP. Sector-wise coal demand as assessed with the above approach for the two scenarios are given Future coal demand

56. Production Plan Considering high growth in coal demand, either as per Coal Vision 2025, or as per the estimates of the Administrative Ministries of coal consuming sectors, there is a need to increase the availability of coal from the indigenous sources. With this in mind coal production programme in different “PlanPeriods” has been worked out. Coal demand (with8% growth of GDP), as per Coal Vision 2025 document, is expected to rise to 1267 million tonnes per annum by 2024-25.

57. Deep u/g mines Deep mines (+450 to 500m depth) Bad roof conditions Gassy seams Ventilation Environmental monitoring Water logged areas Large o/c mines More depth up to 500m with SR 1in 7to15 High capacity equipment, 40 Cum shovels, 80 Cum D/Lines, large dia drills, 240 T dumpers Highly productive mines, 20/30/4 mill te High consumption of explosive No of blasts

58. Existing legislative provisions do not match with the newer technology Standard or safe operating procedures are yet to be developed leading to safe operations Work persons are not educated, skilled or trained to adopt such new technology enhancing chances of more human error Legislative provisions

59. Gradual shift from prescriptive legislation of the present to a goal setting legislation with built in-mechanism for risk assessment and formulation of safety, health and environment management plan Develop more flexible regulation with simple and easy process for amendment to keep the regulation updated and pace with changing need of industry

60. Various levels of participation Workmen’s inspectors Mine level safety committees – Monthly meetings Area level Bipartite /Tripartite safety committees – Bi-annual meetings Subsidiary Company level Tripartite safety commitees - Biannually Coal India safety Board meeting – Biannually Standing Committees on Safety in Coal Industry – Biannual meetings Chaired by MOC

61. Shortage of manpower No study available as yet? CIL has 371546 employees on Mar’13 Supervisors-37855 Workers-334359 Executives-156431 Total(Mar’2010)-387645 CIL plans to recruit 3000 exe per year Shortage of executive is 4000 7 to 8K employees leave every year 700 to 800 exe leave CIL every year There was recruitment holiday in CIL for 12 years Total m/p in mining industry- 1.00 mill

62. Most of the VRS/leaving co comes from u/g mine all category, skilled,semi skilled and un skilled. The plan to produce 150 MTPY from u/g may fail as hardly any person shall be available for u/g MPT require high skill and if nothing is done for skill development or training to enhance skill there is answer from where u/g coal would come.

63. Environmental damage Land degradation De-forestation Polluted air/water Noise pollution Re-afforestation we cut a (?) old tree and plant a sapling Land scape Obstruction to sight Community Rehabilitation/resettlement

64. Private blocks and out sourcing Coal blocks & contractors workers. Mar’2011 out 194 blocks 86 were scheduled to produce coal. Only 28 blocks were in production. Produced 36.80 MT coal in 2012-13 against a target of 42 MT. Was 7% of India’s production of 557.5 MT. Since FY 2007 (17.61 MT) growth is (+) 200%. These blocks have important role in bridging gap in demand & supply.

65. These mines are extensively worked by out sourcing. so actual accidents statistics may not be available of such mines. No of contractors workers are not available to make scientific studies of any kind. With such mines real challenge is if are we not entering in the same old golden era of pre-nationalisation. Will we lose the objectives of nationalization ?

66. Thank you all For having heard me so patiently

68. Predominant cause of accident U/G mines: Fall of roof-44.60% Fall of side-14.14% Rope haulage-16.91% Other transport machinery-2.62% Machinery other than transport machinery -2.48% Explosive-4.37% Fall of persons-5.40% Others-