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Review of study on Risk Assessment and

Safety & Health Management Plan for

Munsar Mine of MOIL Ltd

Submitted to

Prepared By

Kratin Solutions Pvt. Ltd. Nagpur

(November, 2015)

Review of study on Risk Assessment and Safety & Health Management Plan Munsar Mine, MOIL Ltd.

Kratin Solutions Pvt. Ltd 2

Preface Work order no.Sr. DGM (M)/W.O.-Risk Assessment/14-15/129 Dated 17/09/2014 was

issued to Kratin Solutions Pvt. Ltd, Nagpur by M/s. MOIL Limited, Nagpur for Review of the

study on Risk Assessment & Preparation of Safety &Health Management Plan for MOIL

mines as per requirement of DGMS Circular No. 13 of 2002.

The Kratin team consisting of Sri S. N. Katiyar and Sri S. V. Joshi (Mining), Sri C. P. Varma

(E&M), Sri A.C. Ray (Environment) and Sri Suhas Ramtekkar, Geologist, visited Munsar Mine

from 27th-28thApril 2015for review of the earlier study on Risk Assessment and preparing

Safety & Health Management Plan.

During the mine visit, the Kratin team inspected underground workings, opencast dump

workings, Magazine, Mine workshop, Mine Hospital, Group V. T. Centre and other surface

infrastructure and had discussions with the Mine Manager, Safety Officer, Engineer

(electrical/mechanical), Medical Officer and other supervisory staff of the Mine regarding

the existing permissions and practices being followed.

On the basis of the said inspection, status (as on the date of inspection) of

implementation of the risk management action plan suggested vide earlier study report

prepared by M/s Pollution & Ecology Control Services, Nagpur, has been tabulated. The

assessment of risks and hazard identification has further been reviewed to delete/modify

the earlier identified hazards and assess the new hazards and associated risks if any.

A training program on “Health and Safety Management System in Mines” was

conducted by Kratin Team on 27thApril, 2015 combined for Group-III mines (Kandri, Munsar,

Gumgaon & Beldongri Mine) at Munsar Training Centre. 30 officials attended the training.

Methodology of conducting safety audit and risk assessment was explained in details to all

the participants through power point presentations. Interactive question-answer session

was also held at the end of the training.

Based on the above, “Risk Assessment Report and Safety &Health Management Plan” was

prepared as per the guidelines issued by DGMS vide Cir. No.13 of 2002, DGMS Tech. Cir. (MAMID)/

01/2014, Cir. 02/2014 and recommendations of Safety Conferences & draft report was submitted to

MOIL in October 2015. The final Report is being submitted herewith for needful.

I, on behalf of M/s. Kratin Solutions Pvt. Ltd., express sincere thanks to the

Management of Munsar Mine for all the help & courtesy extended to us to make our task

easier.

S.N.Katiyar,

President and CEO,

Kratin Solutions Pvt. Ltd.



DISCLAIMER

This report is strictly private & confidential and has been prepared for the

exclusive use of MOIL Ltd.

The report has been prepared by Kratin Solutions Private Limited on the

basis of their teams visit to Munsar mine from 27thto 28thApril, 2015 as well as

information received from the officials of the Munsar Mine of MOIL Ltd. Kratin

has made best endeavors to verify the accuracy of information provided in this

report. No blame or responsibility should be attributed to Kratin for any

factual errors or misinterpretation of data received and used by Kratin.

******************



Table of Content

Preface ................................................................................................................................................................................... 2

DISCLAIMER ....................................................................................................................................................................... 3

Chapter - I ............................................................................................................................................................................ 5

Introduction ........................................................................................................................................................................ 5

General Information of the mine: ..................................................................................................................... 6

Chapter II ...........................................................................................................................................................................12

Review of earlier study of Risk Assessment at Munsar Mine .......................................................................12

Chapter - III .......................................................................................................................................................................44

Safety & Health Management Plan ..........................................................................................................................44

Chapter - IV .................................................................................................................................................................... 128

Recommendations....................................................................................................................................................... 128

Annexure ......................................................................................................................................................................... 134

Permission granted under Reg. 107(3) MMR 1961 for carrying out stoping operations (Annexure-I-1) .............................................................................................................................................................. 135

The Environment Clearance (EC) for Munsar mine has been obtained (MoEF), Govt. of India vide letter no. J-11015/413/2007-IA.II(M) dated 26.12.2007, for a capacity of4166 TPM involving a total lease area of 149.06 ha (Annexure I-2).................................................................................................... 139

Consent to Operate (CTO) was obtained vide letter dated 15.01.2013 (Annexure I-3) ................ 145

4 nos. ambient air quality monitoring stations have been established at Munsar Mine. Quarterly air monitoring at these locations is being done by external agency M/s Anacon Laboratories, Nagpur (Annexure I-4) .............................................................................................................................................. 150

The water quality parameters tested are – pH, Dissolved Oxygen, COD, BOD, Suspended solids, Oil & Grease, manganese. (Annexure I -5)......................................................................................................... 153

Noise monitoring is done at 4 points viz. UG pit, haul road, jack hammer drill & Ventilation Fan on quarterly basis by an external agency M/s Anacon Laboratories, Nagpur (Annexure I-6) ... 154



Chapter - I Introduction

For conducting Risk Assessment, Kratin team consisting of Sri S. N. Katiyar, Ex. Dir

(Tech), BCCL, Sri S. V. Joshi Ex. Dy. Chief (Mines) MOIL, Sri A.C. Ray Ex-GM (Environment),

WCL, Sri C. P. Varma, Ex-Supt. Engineer (E & M) WCL& Sri Suhas Ramtekkar, Geologist,

visited Munsar Mine of MOIL Limited from 27thto 28th April, 2015. During mine visit the

team had discussions with the Mine Manager, Safety Officer, Surveyor, Engineer, Workmen

Inspectors and other supervisory staff of the mine regarding existing permissions and

practices being followed.

Kratin Team discussing with the Mine

Manager

Kratin Team visiting Munsar mine for Risk

Assessment

For reviewing the status of implementation of earlier Risk Assessment study & risk

management action plan, the following aspects of existing mining activities at Munsar Mine

were studied:

Men & material winding/Haulage;

Ventilation and Fire control System;

Drilling and blasting;

Strata control in underground stopes (Timber support/Roof Bolting in haulage roads, crosscuts);

Transportation of ore belowground/ Locomotive transport;

Hydraulic Sand Stowing;

Water management (Pumping);

Transportation of ore on surface (Contractual as well as departmental);

Maintenance of Benches in dump mining;

Haul road maintenance;

Stabilization of the walls;

Stability of dumps;

Loading and Transport systems in Opencast workings/Secondary recovery from dumps;

Manual Ore sorting;

Loading of material on surface;

System of Illumination;

Environmental monitoring;

System of airborne dust survey and dust suppression;



Compliance of statutory provisions related to occupational health surveillance/ IME/PME etc.;

System of operation & maintenance of machines;

Existing statutory manpower& further requirements, if any;

Provision and use of personal protective equipments;

Power supply system;

System of maintenance and Inspection of electrical relays. Earthing System, Lightning arrester etc.;

Electrical Safety system as per Central Electricity Authority Regulations, 2010;

Emergency preparedness, response &Communication system;

Rescue& Emergency organization;

Framing and implementation of Safe Operating Procedures & Code of Practice, standing orders etc.;

Functioning of Safety Committee & Workmen’ Inspectors;

Maintenance of Statutory Plans;

Maintenance of Statutory records;

Analysis of accident statistics of last five years;

Work place safety including safety while working at height.

General Information of the mine:

1. Name of the Mine Munsar Mine, MOIL Limited 2. Address of the mine Post- Khairi Bijewada,Tah. Ramtek,

Dist- Nagpur (M.S.) 441 106 3. Mining Plan/Scheme approval

details Scheme of Mining approved vide IBM letter no.NGP/MN/MPLN-257/NGP dated 16.4.2013

4. Nominated Owner Shri A. K. Jha Director (Production& Planning)

5. Agent Shri A. V. Masade, Dy. G.M. (Mines) 6. Mine Manager Shri R.A. Khan,Chief (Mines) 7. Safety Officer Shri S.B. Ramteke, Sr. Manager (Mines) 8. Names of Workmen

Inspectors Mining Mechanical Electrical

Sri Ravi Thakur Sri Suresh Yadav Sri S. M. Ghadyalji

9. Details of working ore body- Strike length about 2.7 km Average thickness 6m, Ore- Braunite,

10. Inclination of the ore body 700 11. Total lease hold area 149.06 Ha 12. Geological Reserves 4639267 tonnes as on 01.04.2014 13. General strike & dip direction N600W-S600E 14. Permission granted under Reg.

107(3) MMR 1961 for carrying out stoping operations

(Annexure-I-1)

15. Year of opening 1889 by opencast and since 1954 by underground

16. Average daily employment 134 (departmental) 17. Average Daily Output 200 TPD 18. Mine Opening RL 348 mRL

19. Present working Level as on date 31.12.2014

303 mRL



End use of Ore:

Manganese Ore of Munsar Mine is used for making steel.

Location, approach & communication:

Munsar Mine is situated in Nagpur District of Maharashtra State. Munsar town is 45 kms. Away from Nagpur on the Nagpur Jabalpur National Highway No. 07 toward NW. Ramtek Railway Station is 1 km away from the mine. The latitude and longitude of the centre is 210 23’ 22” and 790 17’ 14”.

Geology and structure:

The Manganese Ore in this area occurs in the Munsar stage of Sausar series. The Sausar series of rocks belongs to Dharwar (Archean) age group and are probably amongst the oldest rocks known is Indian Geology. There is only one ore horizon in the area under report. Repetition of any ore horizon is due to folding or in some cases by faulting. There is little evidence of major structural folds in the area mapped. Intense drag folding is noticeable anywhere in the softer schists and schistose gneisses but the harder gondite appears to have withstood this. At one or two places, such as at Ch. 2000 and 2750 the ore horizon seems to have given way and more incompetent sediments (the present schist and schistose gneiss) which were probably semi-plastic at the time of formation have been transformed into a fold through the gap. The only factor that complicates the structure of the ore body in Munsar Mines is a set of step, slightly oblique strike faults. The faults are all well-defined, with fairly crushed. In some cases it is possible to study the direction of relative movement on the fault planes with the help of little folds and wrinkles developed due to drag fold. Reserves (As per UNFC) in tonnes as on 01.04.2014:

Category In-situ Reserve (In Tonnes)

Proved Mineral Reserve 1,13,585

Probable Mineral Reserve 6,20,670

Pre-Feasibility Mineral Reserve 24,55,527

Inferred Mineral Reserve 14,49,485

Total 46,39,267

Method of Working:

This Mine has got a characteristic of being opencast working of old dump as well as underground working. The strike length of ore body is 2.7 Km. with the direction East & west. Mining of ore by opencast method was started from 1889 and by underground since 1954.

Underground Mining:- The underground section consists of mainly 70’ level which is worked by means of incline driven at CH: 200. The total length of incline from brow point is 90.0 Mtrs. The size of the Incline is 4.9 Mtrs. having inclination of 300. The R.L. of Incline brow is 348 Mtrs. and Incline bottom i.e. 70’ Level is 303 Mtrs. haulage road of size 2.10 mtrs. x 2.10 Mtrs. has been excavated upto Ch. 700 in H/W rock. This portion of the Haulage road has been supported by girders fixed in square manner in 0.3 Mtrs. Interval having the size of R.S. Joist 200 mm x 100 mm. After CH. 700 the ore drive is being utilized as Haulage Road. The stopes have been prepared by driving stope drive, leaving 5 Mtr. sill pillar above the Haulage road of 70’ level. Number of winzes has been sunk between 170’ Level and 70’ Level for facilitating filling supply, ventilation and 2nd outlet for the respective block. Manways and ore pass have been constructed as per the convenience of men and materials as well as for the purpose of



ventilation between the stope and Haulage Road. The ladder ways and ore chutes constructed with 10 mm thick steel fabricated and are raised gradually as the stope goes up. Stoping permission has been received for the area between CH. 1850 to CH. 2650

and between CH. 2650 to 2850 at 70’ level. The stope from CH 850 to CH 2400 is exhausted

and at present stoping operation is being carried out from CH. 2650 to 2850.

Drilling & Blasting:

Drilling is done by hand held Jack Hammer drills; Holes of 32mm diameter, depth 0.8m

– 1.5m are drilled at spacing &burden of0.8m each. 25mm Cartridge explosives are used to

blast the same using electric detonators.

After blasting, the faces are dressed to remove any loose fragment and weak portion

from the roof as well as sides.

Magazine:

Magazine license No. : E/HQ/MH/22/471(E-33511) valid up to 31/03/2019. Magazine capacity

1.) Nitro mix : 7500 Kg 2.) Safety fuse : 3000 Mtrs 3.) Detonators : 30000 Nos. 4.) Detonating fuse : 14500 Mtrs a) Storage of explosive is being done as per related rules. b) Transport of explosive is being done in explosive van with approved license from

Explosive Dept. c) Explosive is issued through Indent given by Mine Manager/Asst. Mine Manager of

concerned Mines.

Strata Management: 1. Props are erected in the working faces within a distance of 4 m from the face. 2. Chocks are provided at a distance of 3 m. 3. Rows of the props are also at a distance of 3 m. 4. Nearest chocks from the face is at a distance of 4 m.

Mucking and Transportation:

Mucking is done manually. Side tipping tubs of 16 cft capacity are loaded and tubs are

hauled by battery loco upto the pit bottom.

The ROM obtained from stope is hauled up from 70’ level to surface by 50 HP double

drum haulage.

Power supply and Electrical installations:

Source of power supply:

11 KV supply through OH line is received from MSEPCL to11 KV Sub-Station.

Observations and comments:

Single line diagram has not been displayed at the sub-station. There was no attendant at the

11 KV sub-station. Lightning arrester has been provided but earth pits need to be made both

at the receiving as well as sending end in accordance with Rule 97 of CEAR 2010.



The earthing lead for any lightning arrester shall not pass through any iron or steel pipe but

shall be taken as directly as possible from the lightning arrester to a separate earth

electrode and/or junction of earth mat avoiding bends wherever practicable.

Separate earth pits be provided for individual transformer, transformer neutral, transformer

body and switchgear and every earth pit be marked as:-

Earth pit no.

Neutral for transformer with identification

Resistance value

Date of testing.

The resistance values of each and every earth pit have to be maintained below 1 ohm.

Periodical test has to be conducted at least once every year in peak dry weather (Peak

summer) and recorded (Rule 67).

Ventilation System:

The mine is ventilated by means of an electrically driven 3000 cum per minute capacity axial

flow fan located at 270’L at winze no. 2. The vertical shaft, the winze at Ch.600, and 70’ L

incline serve as intake.

An Assistant Manager has been authorized as ventilation officer to supervise the

maintenance of ventilation system. The standing orders in the event of stoppage of these

ventilation fans have been framed and displayed in the fan houses. Effective double door

air lock with rubber lining is provided at both the Fan Houses.

The Following instruments are available at the mine for carrying out the periodical

ventilation survey:

A) Anemometer.

B) Hygrometer.

C) Stop Watch.

One no. generator is available at the mine as an alternate source of Power supply. Air

measurement stations are fixed at intakes, returns and in cross cuts near all working stopes.

Ventilation Survey is done at regular interval. The stope ventilation is effected by coursing

the fresh air through the Manways/Ore passes and the air returns through the respective

stope winzes to the upper level return airway.

Environment Environmental Hazards associated with Manganese Ore mining:

Manganese Ore mining is likely to generate Air Pollution, Water Pollution, Noise

Pollution and Land degradation due to drilling, blasting as well as transportation, surface

run-off, subsidence etc., which can cause adverse impact on the surrounding environment,

flora and fauna.

The total lease hold area of the mine is 149.06 ha.At present Munsar mine is worked mainly

by underground method. Additionally, dump mining is being done in a small area.

The Environment Clearance (EC) for Munsar manganese ore mine of MOIL has been

obtained from Ministry of Environment & Forests (MoEF), Govt. of India vide letter no. J-



11015/413/2007-IA.II (M) dated 26.12.2007, for a capacity of4166 TPM involving a total

lease area of 149.06 ha (Annexure I-2).The EC is granted subject to compliance of a set of

conditions in a time-bound manner.

Further, Consent to Operate (CTO) was obtained vide letter dated 15.01.2013 (Annexure I-

3) which is valid upto 30.6.2015. Application for renewal of CTO has been submitted to

MPCB but till date renewal of CTO has not been granted.

Air Pollution and Control:

The Air Pollution caused by mining and Control measures taken by the mine management

are discussed below –

Observations& Comments:

a) Generation of dust was observed at the dump mining site, ore transportation road,

and waste dump area.

b) Dust suppression in underground working is done by wet drilling, and, by thoroughly

wetting the back, hanging wall, footwall.

c) Ventilation fan (3000 cum capacity) is installed to carry away the air pollutants from

the underground workings.

d) A water tanker of 5 KL capacity is being used for water sprinkling on road.

e) 4 nos. ambient air quality monitoring stations have been established at Munsar Mine

(Mine pit, Mine office, Staff colony & Mine Hospital). Quarterly air monitoring at these

locations is being done by external agency M/s Anacon Laboratories, Nagpur and

reports are sent regularly to MPCB and MOEF. (Annexure I-4)

f) Personal dust monitoring is carried out on workers at UG six-monthly. It should be

done for surface workers also.

Water Pollution and Control:

The Water Pollution caused by mining and control measures taken by the mine

management are discussed below –


i) Catch drains/garland drains were provided. They should be de-silted regularly before

monsoon and made sufficiently big to cater to the surface run-off.

ii) Mine effluent (mine discharge water) from underground pits is pumped to surface and

stored in a tank for re-use in dust suppression, sand stowing, plantation, firefighting etc.

Settlement of suspended particles takes place in underground sumps and surface tank.

iii) Oil & grease trap should be provided in the workshop.

iv) Water quality is monitored quarterly by an external agency M/s Anacon Laboratories,

Nagpur.

v) Bio-medical wastes should be disposed as per latest Biomedical Wastes Rules.

vi) The water quality parameters tested are – pH, Dissolved Oxygen, COD, BOD, Suspended solids, Oil & Grease, manganese. Test for drinking water/water potability test is not done. (Copy of Water monitoring reports enclosed at Annexure I -5).

vii) Potability test for dug-well water used for drinking purpose should be done immediately

as per IS: 10500 and as recommended by the 10th safety conference.



Noise Pollution:

The noise pollution caused by mining at Munsar mine and control measures taken by the

mine management are discussed below –


Noise monitoring is done at 4 points viz. UG pit, haul road, jack hammer drill &

Ventilation Fan on quarterly basis by an external agency M/s Anacon Laboratories,

Nagpur (Annexure I-6).

As per quarterly noise report, noise level at jack hammer drill (UG) has exceeded 100

dB(A) in Sept & Dec.’2014.

Noise mapping to establish high noise areas is not done. Noise dosimetry to measure

personal noise exposure is not done.

Machinery should be maintained in good working order every time to reduce noise.

Ear plugs/muffs have been provided by the management to the workers as informed

but it was observed that they are not used by workers working at high noise zones

like jack hammer drill, ventilation fan etc. Workers should be educated to use ear

plugs/muffs as per statute

Subsidence Monitoring:

Study on subsidence and stage-wise development plan has not yet been done and

submitted to MOEF. Subsidence monitoring is done on the basis of physical inspection only

of water bodies, structures etc.

Management informed that till date no subsidence movement has been noticed.

The underground mine voids are filled with sand by stowing thereby minimising the

occurrence of subsidence.

Accident Statistics & Prevention

Accident record for the last 3 years:

Item Sl.

No Description 2012 2013 2014

Acc

iden

t

Stat

isti

cs 1 No of Fatal Accidents 0 0 0

2 No of Serious Accidents 0 0 0

3 No of Reportable Accidents 2 2 2

4 Total No of Accidents 2 2 2


As per the information made available to the risk assessment team, during the last

three years there have been no serious or fatal accidents at the mine. However, there

have been reportable accidents two each during 2012, 2013 and 2014.

*********************



Chapter II

Review of earlier study of Risk Assessment at Munsar Mine

Study of Risk Assessment and preparation of safety management plan for Munsar Mine of

MOIL Ltd was done by M/s Pollution and Ecology Control Services, Nagpur during 2009-10.

Action plan to manage various risks at the mine was recommended by them. Status of

implementation of the action plan as observed by Kratin is tabulated below.

Table no.11- Risk Management Action Plan to prevent accident due to ground movement:

Sr. No

Sub-activity Mechanism Recommended Action vide earlier study report

Status as observed by Kratin team

1.0 1.1 Provision of adequate support geologically disturbed area.

1.1.1 U/G Mining 2 shift work

1.1.1.1 A-1 Advanced study by Strata Control Cell of HQ about change of RMR and revision of SSR to be done.

Study about change of RMR not done. Details of strata control cell were not available.

A-2Manager’s guidelines/instruction shall be prepared specifying actions to be taken and assign specific responsibilities to all under him.

The SSR specifies system of support for geologically disturbed area; however, specific responsibilities not assigned.

1.2.1.1 A-1 The support design to be based on RMR/Rock characteristics. A-2 Review of RMR to be done at regular interval and whenever there appears to be change of roof condition and SSR to be revised on every occasion.

Support design is based on the RMR/Rock characteristics study conducted by NIRM. Review of RMR not done.

1.3.1A. Non-compliance of procedures/Rules in (A) Testing of Roof/Side.

1.3.1A.1 A-1 Testing of roof and sides to be done with the help of gadget/instrument for a place already supported. A-2 The support personnel to be trained for testing.

No gadget or instrument is used for testing of roof and sides; same is tested using crow bar and examining the sound of the roof. Support personnel are given refresher training as required under the V.T.Rules.

1.3.1B Dressing & Trimming of Roof/Side.

1.3.1B.1 A-1 Manager to formulate guide lines for selection of dressers. Existing one to be reviewed based on DGMS Cir No.6 2002. A-2 Area Training Officer to organize training for development of skill of the dressers.

No such guidelines have been documented for selection of dressers. The dressers are given refresher training as required under the V.T.Rules.

1.3.1B.1 A-3 Manager’s instructions in writing to AM/UM for efficient

Sufficient number of persons have been trained in roof dressing



distribution of dresser. A-4 Positive action to reduce absenteeism and to provide suitable substitute.

to take care of the absenteeism on account of leave/sick/other reasons of the regular dressers.

B-1 Adequate tools of sufficient length to be provide to dressers (at least 1.8m)

Crowbars of 2m length, in sufficient number have been provided.

C-1 Mate and Foreman to carry out their duties and checking of roof and side condition to be done by improved aides (Roof testing machine)

No roof testing machine has been provided. Mate & Foremen are visually checking the roof & side condition and getting the roof tested by conventional crow bar tapping method.

D-1 Manager shall formulate guidelines for carrying out dressing operations. Precautions like use of long crow bars, standing on the rise side, working only beneath supported roof, deployment of minimum number of persons and provision of good light as recommended by D.G.M.S. Cir.

SOP for dressing has been formulated and being implemented.

0110 0111 0112 0113

E-1 Surprise inspection to be done by AM/UM. E-2 Surprise inspection to be done by the Manager. E-3 Disciplinary action to be initiated for non-compliance / non-performance

Surprise inspections are done by the AM/UM and Manager, however, record of surprise inspections not maintained.

F-1 Agent to take up with the HQ for evolving suitable incentive scheme if not existing.

Not implemented.

G-1 The report of Supervisor to be checked by AM/UM and report of AM/UM to be checked by the Asstt. Manager I/c and action to be taken.

System being followed.

Support setting as per procedures &rules.

1.3.1 C Support setting-wrong method/delayed setting.

1.3.1C.1 A-1 The Manager shall frame standard procedures for support setting and circulate in local language. A film on the problem to be prepared.

SOP formulated, film (audio-visual) on support setting not prepared.

A-2 The fm/mate is to ensure that the supports are maintained tight against the roof/side at the work place.

Being ensured

B-1 Manager to specify the The first row of



allowable support free front and how to adhere to this system by keeping support up-to-date.

cable/rock bolt is specified to be not more than 1m from the face/front end of the slice at any time.

B-2 The supervisors to report AM/UM if support lag is beyond the specified support free front on phone.

Support lag is being communicated to the AM/UM by the supervisors and in turn to the Manager. B-3 In bolting system lag on

support more than 2m at any shift be reported to manager by AM/UM.

B-4 FM’s have to maintain support plan & to be updated in each shift.

Not implemented

B-5 AM/UM to make inspection daily to see the condition of support and lag if any.

Daily inspection is being exercised by AM/UM.

1.3.1C.1 B-6 Lag on support more than 2m to be recorded in the daily report besides informing the Manager on phone by AM/UM. No person shall be Allowed to work at the place with support lag more than 2m.

No regular system of reporting such incidents

B-7 The Manager to get feedback on supports lag or other problems of supply etc. and to take timely action.

On being reported, Timely action is being taken on support lag or other problems of material supply etc. by the manager.

C-1 Agent/owner to ensure adequate number of machines.

Being ensured

D-1 Agent to ensure adequate supply of drilling accessories.

Being ensured

E-1 Engineer to ensure timely and correct maintenance of equipment.

Timely and correct maintenance of drilling equipment is being ensured.

F-1 The agent to ensure adequate supply of roof support material.

Adequate support material is available.

1.3.1D. Support rule execution, supervision and control.

1.31.D.1 A-1 The Manager to ensure that a copy of support rule is circulated to all concerned and rules are being followed.

Copies circulated to all concerned and SSR being followed.

A-2 The Manager to issue specific instructions to AM/UM to ensure compliance.

Specific instructions issued to AM/UM regarding support of the workings as per the SSR.

A-3 FM & MS to ensure that supports are erected at the right

Being ensured



time as per SOGs and support rules are complied with.

Support rules executing (contd.)

1.3.1E Monitoring of Support effectiveness.

1.3.1. E.1 A-1 Regular monitoring of performance of support/bolting efficiency (at least 10%) by anchorage testing. Regular use of Torque wrench for bolt tensioning.

Anchorage testing being done regularly.

A-2 Sag measurement by Tell-tale or any other suitable type of instrument for monitoring support adequacy.

No instrumentation provided for monitoring of support adequacy & quality.

1.3 Support setting/withdraw-al as per Procedures & Rules.

1.3.1F Support withdrawal

1.3.1F.1 A-1 The Manager shall prepare a scheme on guidelines for withdrawal and resetting under different circumstances and assign specific responsibilities to executives and supervisors.

Scheme or guidelines not prepared.

1.4 Provision of adequate support at work place.

1.4.1A & 1B Activities carried out without providing adequate support during (A) Manual Loading/mucking

1.4.1A&1B.1 A-1 The Manager shall frame procedures for cleaning of falls or mucking of ore at face with instructions not to load/clean up manually under unsupported roof.

Procedure framed but not being properly recorded in writing.

Providing adequate support.

A-2 The Foreman/Mate shall ensure that the procedures are followed.

Being ensured.

1.4.1A&1B Transportation - Manual

1.4.1A&1B.1 B-1 The Manager shall frame procedures specifying when the workers would be allowed to enter the face after blasting.

Procedure not framed but workers are being allowed to enter the face after inspection by the mine mate.

B-2 The FM/Mate are to ensure that the procedures are followed.

Being ensured.

1.5 Position of quality materials

1.5.1 Poor quality of support materials.

1.5.1.1 A-1 Agent to ensure correct management of materials.

Being ensured

B-1 To monitor that material on demand from mine supplied in time.

Material being supplied in time.

C-1 To monitor that the correct quality/materials maintained.

Only DGMS approved quality material is procured.

D-1 To monitor that the specifications are complied with.

1.6 Supervision of all operations by skilled/competent persons.

1.6.1 Lack of competent operating personnel

1.6.1.1 A-1 Rule & job Training to be good quality.

Being ensured.

A-2 Workmanship examination & certificate to be through.

No procedure developed.



Table no. 12- Risk Management Action Plan for control of accidents/loss of property by inundation

Sr.No. Sub-Activity Mechanism Action Plan Status as observed by Kratin

1.0 1.1 Inundation planning and execution of drainage and pumping system

1.1.1A (i) Inrush of water through breach of embankment of barrier/drains/nullah etc.-overflow. Inadequate sump capacity.

1.1.1A(i) a-1 Carry out levelling to prepare contour map of the catchment area every year well before monsoon.

Implemented

a-2 Drainage system and sump in surface/opencast workings were all provided and pumps of adequate capacity were installed. Details are given in the Note on inundation. Action as proposed in the DI plan enclosed.

Implemented

a-3 Prepare monsoon preparation plan for repair, construction of all drainage system and ensure completion before onset of monsoon.

Being implemented every year before monsoon.

b-1 Plan for sump capacity and pumping capacity to deal with max. Rain fall prepared.

Sump capacity and pumping capacity are adequate to deal with max. Rainfall.

b-2 Prepare Layout of pumping installations – completed.

Implemented.

b-3 Prepare action plan on monsoon preparation and complete execution before monsoon. Completed.

Implemented

b-4 Prepare action plan on repair & maintenance of pumps and complete execution before monsoon.

Implemented.

A-3 Advance manpower planning to be done for regular appointment of trained personnel.

Advance manpower planning being done.

1.7 Man power planning –Adequate No. of trained personnel

1.7.1 Shortage of trained manpower even for the key jobs.

1.7.1.1 A-1 Same as above under S.N 1.7.1.1-A-3

1.8 Provision of adequate fund/finance

1.8.1 Shortage of fund even for important safety materials.

1.8.1.1 A-1 To identify the unnecessary & unplanned expenditure & initiate action for education.

Action is being taken for optimization of use of funds.

B-1 To monitor funding on all operations.

Being monitored



2.1 Inundation planning and execution of drainage and pumping system

c-1 Make standing order for withdrawal of person and machineries in case of emergency- completed. To be executed as required.

Standing orders framed.

c-2 Prepare inspection schedule for inspection by officers during heavy rains. Should be prepared as per DG’s Cir. 2/1978 and complied with during monsoon.

Implemented.

1.1.1B Inadequate pump capacity/failure of pumping

1.1.1B(i) a-1 All pumps to be overhauled and new pumps where required to be added before monsoon- completed.

Being carried out

b-1 Emergency operation for withdrawal of machineries including pumps if required to be started

Being implemented as and when required.

1.1.1C (i) Unplanned drainage system- provision of drain, laying of pipeline etc.

1.1.1C(i) a-1 Survey of the area before monsoon to be completed and all drainage system to be finalized - completed. This should be completed before one month of next monsoon.

Implemented.

a-2 Drainage plan to be executed before monsoon.

Implemented.

2.1.1D (i) Incomplete civil construction work for new drain, repair of old drain etc.

2.1.1D(i) a-1 The civil construction work to be completed before monsoon on priority basis – necessary action to be taken immediately.

Being implemented as and when required.

2.1.1E (i) Physical injury due to impact by water or by drowning.

2.1.1E(i) a-1 Warning system to be introduced to warn the people before heavy shower.

No such system exists.

a-2 Scheme on withdrawal of persons to be also prepared and executed.

General plan of action in emergency for withdrawal of persons has been prepared.

2.1.1F (i)Shock/electrocution during work in pumping station in water/during rain/ pump

2.1.1F(i) a-1 Before starting work on shifting, shut-down of power supply to be undertaken first and in addition earth continuity and cable rating to be checked.

Being implemented.

b-1 Standard Implemented.



shifting. procedure/guidelines already framed and enclosed at Annexure vol. 2/2 to be implemented.

2.1.1.G Maintenance of accurate and up-to-date plan- irregular

a-i) Manager shall ensure that survey is carried out and plans are maintained upto-date.

Implemented

2.1.1.H Regular monitoring, supervision, control and management – deficient.

a-i) Management system to be improved to ensure effective control and execution of DI Plan, including Emergency Response System.

Effective control and execution of DI Plan ensured.

Table no. 13- Risk Management Action Plan to prevent accidents due to use of u/g machinery ( 2 shift operation)

Sr.No Sub-Activity Mechanism Action Plan Status as observed by Kratin

1.0 1.1 Maintenance and replacement of haulage track by quality parts

1.1 Maintenance - poor

Regular planning and execution for procurement and replacement of track parts by quality

Being implemented

1.2 Good supervision, control and management

1.2 Good Supervision, control and management – deficient

Management system to be improved to ensure regular monitoring, control and management

Being Implemented

2.1 - Drilling of holes (Face) - Drilling of holes (Roof) - Pumping operation (Normal and sand stowing)

2.1 A Drilling machine and pumps. (i) Helper’s error (hit by fallen pieces) (ii) Getting trapped in between side & machine.

2.1A (i&ii) A-1 Helper should work as per code of practice on operation

Being ensured

2.1 B. Negligent driving

2.1 B-1 A-1 Work with care & attention is desired and to be ensured.

Being implemented

B-1 The driver should be skilled and competent to carry out the duties.



2.1 C. Caught/pressed in between moving parts.

2.1.1C.1 A-1 Helper to control other people around machine as per code of practice to be prepared.

Being ensured

A-2 Foreman & A.E. (E&M) to ensure compliance of code by operator and helper.

2.2.1 A. Hit by/fall of material/cable during handling/ repair/ maintenance

Same action as under S.N. 1.2.1. General action-

- Compliance of safe code of practice on repair, maintenance and installation.

- Maintenance of electrical parts and trailing cable in good order.

- Compliance of safe code of practice on good housekeeping.

- COP enclosed at Annex Vol 2/2

Being implemented

B. Slippage of tools

C. Electrocution/ Shock by trailing cable/ machine body

D. Poor house keeping

E. Poor maintenance procedures.

Table No. 14: Risk Management Action Plan For Prevention Of Accident Due To Use Of Explosives –U/G

Sr.No. Sub-Activity Mechanism Action Plan Status as observed by

Kratin

1.0 Blasting by use explosives. Two shifts operation But blasting in 1st shift. Blasting when two galleries are approaching within 10mtr. To each other

1.1 (i) Use of explosive of unapproved type/ beyond shelf life. 1.1.1B (i) Pre-detonation during transport of explosives.

1.1.1A(i) a-1 Suitable type of explosive within shelf life to be used. 1.1.1B(i) a-1 Approved type of vehicles to be used for transportation of explosives.

Being implemented.

Licensed explosive van

is used for transport of

explosives within the

mine.

b-1 The statutory & recommendatory provisions for transport and handling of explosive shall be complied with.

Being complied.

1.1.1C (i) Entry of personal within

1.1.1C(i) A-1 Warning signal to be provided & maintained.

Blasting is done at the

end of shift after

putting red flags on all



the danger zone due to inadequate warning to all concerned.

entry points and giving

the warning.

b-1 Posting & withdrawal of Guards to be regulated as per CARD system in force.

Card system not

implemented.

1.1.1.D Injury due to thrown off fly rocks during blasting . Injury due to blown through shots.

1.1.1 D (a) 1 Strict supervision (a) 2 Withdrawal of person and posting of Guards as per card system.

Strict supervision is

exercised however,

Card system is not

being followed.

1.1.1.E Good Supervision, control and management - deficient

Action as proposed under control.

Being implemented

Table no. 15: Risk Management Action Plan to prevent accidents due to ventilation and fire.


Kratin

1 1.1 Working of machines in u/g using inflammable fuel, battery operator, blasting – use of explosive.

1.1.1A (i) Inadequate monitoring in detection and control measures.

1.1.1A(i) a-1 Automatic detection of fire and control measures viz. fire detector, extinguisher, quenching by water JET and use of dry cartridges and liquid/gas of CO2 to be made at appropriate places where fire is apprehended.

System for automatic

detection for fire not

introduced.

Fire extinguishers (CO2

type) are provided at

appropriate places.

1.1.1B (i) Poor ventilation- Planning & Control

1.1.1B(i) a-1 Review and planning of ventilation at regular interval based on ventilation survey.

Experts from IIT

Kharagpur have

reviewed the

ventilation system and

their

recommendations are

in the process of

implementation.

a-2 Adequate monitoring of face ventilation as provided in the statutes. A-3 Ventilation survey at least once a year.

Face ventilation is

inadequate and needs

improvement.

b-1 Leakage through various ventilation appliances to be assessed and action taken to minimize leakage.

Implementation of

expert’s

recommendations for

minimising leakages



under process.

b-2 Balancing of pressure if required

Not required.

c-1 Alteration of ventilation shall not be done unless permitted by manager based on ventilation survey

Implemented.

Mentioned in standing

order.

d-1 Ventilation survey/ measurement at faces to be done before deployment of workers as provided in the statutes.

Being Implemented.

1.1.1C (i) Poor emergency response system

1.1.1C(i) a-1 Emergency response plan & organization for FIRE to be prepared on the lines prepared for inundation.

Implemented.

a-2 Simulated emergency exercise to be held at least once in a year.

Not implemented.

a-3 Deficiency observed during above exercise shall be made good by further training and re-training. a-4 Emergency evacuation standing order and standing order for dealing with fire to be reviewed and revised if required after every mock rehearsal. b-1 Efficient communication system between U/G and surface, between surface and outside to be maintained. Example Provide P & T and EPBX

system to connect all possible control points.

In addition to above provide Walkie-Talkie/Siren or mobile phones on surface.

Implemented.

Table No. 17: Risk Management Action Plan For Prevention Of Accident due to Dump mining and

Manual Ore Processing

Sr.No Sub-Activity Mechanism Action Plan Status as observed by

Kratin

1.0 Dump Mining, Boulder Mining

1.1 Failure of bench/ collapse of sides/ collapse of overhang

a) Regular formation of benches with reqd. width and height to be ensured. b) Dressing by the machine to be introduced. c) Use of machine for loading to

Bench height in dumps is restricted to 6m. No overhang observed at the time of inspection



be introduced. d) Formation of overhang in boulder mining to be avoided.

2.0 Breaking & sorting -Big lumpy ore Medium size ore small size ore General shift operation.

2.1.1A Hit by flying pieces.

2.1.1A a-1 Provide metal circular ring around the small & medium size ore.

Metal circular ring not implemented. However, folding three piece screen is provided for protection against flying pieces while manual breaking.

b-1 Helmets, shoes goggles leg –guards are to be provided.

Provided

b-2 Use of PPE to be ensured. Being ensured.

b-3 PPE to be used. Being used.

b-4 Create awareness for use of PPE.

Posters displayed at conspicuous places.

c-1 Breaking should be mechanized.

Not implemented.

2.1.2 Caught Between hammer & stone /ore.

2.1.2 a-1 The workers to be attentive while on the job.

Workers are attentive.

b-1 Correct size hammer & hand gloves to be provided and used.

Gloves and hammer provided but use needs to be enforced.

c-1 Correct procedure of breaking to be followed

Being followed.

d-1 Machine breaking of ore to be introduced.

Not implemented.

2.1.3 Hit by rolling stones.

2.1.3 a-1 Workers not be allowed to work at the foot of high stack.

Being ensured.

b-1 height to be reduced by use of spade.

c-1 PPE to provide. Provided.

d-1 Use of shoes and shin-guards to be ensure.

Safety boots are used; Use of shin guard needs to be enforced.

e-1 Height of Dump to be reduced by machine.

Implemented.

Ore Stacking/loading

3.1.1 Fall on ground by slipping & Tripping

3.1.1 a-1 Worker to be careful and attentive during work.

Workers are careful and attentive.

a-2 Avoid travelling in steep /slippery place.

Being ensured.

3.1.2Hit by fall of ore pieces due to over loading during carrying.

3.1.2 a-1 The workers not be allowed overloading.

Overloading is not allowed.



3.1.3 Hit by fall of ore on body during loading stacking.

b-1 Workers to be careful and attentive during moving with load.


Table No. 18A: RISK MANAGEMENT ACTION PLAN FOR PREVENTION OF ACCIDENT DUE TO TRANSPORTATION MACHINERY – TIPPER TRUCK ROLL OVER. MEDIUM LEVEL RISK

Sr. No.



1.0

1.1 Transportation of ore and O/B

1.1.1a ROLLOVER (i) Break failure steering failure or other ME component Failure/suspension failure.

1.1.1A(i) a-1 Safe code of practice on maintenance and operation for different types Machines/equipment shall be framed revised and to be implemented. Based on specimen copy enclosed.

SOP framed for operation of HEMM

b-1 The management shall ensure regular testing of transportation machinery as per schedule.

Being ensured

c-1 A code of practice for use of brake steering at required places and safe operational procedures under different circumstances shall be included in the main book on operation and maintenance – Code of safe practice of operation.

Not implemented

1.2.1A (ii) (Reversing)

1.2.1A(ii) a-1 Same as under action at S.NO. 1.1.1A (i).

SOP framed for maintenance of HEMM

b-1 “Code of traffic rules” already framed including operational procedures and details of safe reversing procedures.

Implemented

c-1 Different speed with a limit 5km per hour to be enforced

Being implemented

d-1 The operations I/C at working faces and dump yard to ensure safe reversing

Being ensured

e-1 The existing restriction on reversing in haul road except at the designated places to continue.

Implemented

f-1 Adequate lighting to be Provided



provided at the dump yard and near the faces.

f-2 Illumination survey to be done regularly to ensure adequate lighting and records maintained

Not implemented

g-1 The Engineer I/C shall ensure provision of audio-visual reversing alarm.

Being ensured

g-2 The Equipment I/C shall ensure regular checked for proper functioning.

Being checked

h-1 The Equipment I/C shall ensure provision and maintenance.

Being ensured

i-1 The Agent/Eng. (Exc.)/ Manager to arrange for assessment and training.

Not implemented

1.3.1A. (iii) Excessive speed for good haul road conditions.

1.3.1A(iii) a-1 The speed under different circumstances specified in code of Traffic Rules to be complied and to be included in the revised manual in Hindi

To be included in the revised manual in Hindi

b-1 The Manager shall ensure for posting warning sign and barrier at appropriate places and specify maximum allowable speed at other places.

Warning sign specifying the maximum allowable speed not posted.

c-1 Operational procedures to be included in the specimen copy of traffic rules in Hindi.

Not prepared in Hindi

d-1 A team may be formed to carryout surprise check for excessive speed.

Not implemented

1.4.1A (iv) ME movement on unstable ground /dump edge crest edge

1.41A(iv) a-1 The manager shall provide detailed specifications/guidelines for preparation of ground in the dump yard/haul road for safe movement of ME and circulate.

SOP for dumping of overburden framed and circulated.

c-1 In view of anticipated Rollover, access to dump yard base to be restricted.

Access to the dump yard is restricted

d-1 Instructions for compliance of inspection schedule of the work site/dump site as per specimen code of Traffic Rules to be issued.

Implemented.



1.5.1 A improper tyre inflation pressure

3.1.1A(v) a-1 The management should ensure replacement of tyre found unfit after testing.

As informed by the management, unfit tyres are replaced as and when required.

1.0

1.6.1A (ix) Unauthorised Driving negligent driving

a-1 The manager shall issue instruction and arrange publicity against unauthorized driving.

Only authorized operators are deployed for driving the vehicles.

b-1 The management to be rigid in enforcing penalty.

Being ensured.

c-1 Greater Safety Awareness to be created through “quality control on safety”.

1.7.1 A (xi) Fitness for duty

1.7.1A(xi) a-1 The Manager shall issue to all the executives and supervisors concerned to ensure that nobody under influence of drug /alcohol be permitted in duty.

Instructions have been issued to all the executives and supervisors for not permitting intoxicated persons on duty.

a-2 The Manager shall make arrangement for surprise check by MO

No record of surprise check by MO was available

a-3 Limitation for working hours on OT.

Adequate manpower is available.

1.8.1A(xii) Supervision, control & Management - deficient

1.8.1A(xii) The Manager is to issue instructions fixing up responsibility and accountability

Competent supervisors have been authorised mentioning responsibility and accountability.

Table No. 18B RISK MANAGEMENT ACTION PLAN FOR PREVENTION OF ACCIDENT DUE TO COLLISION AND RUNOVER BY TRANSPORTATION MACHINERY- TRUCK, TIPPER ADDITIONAL MECHANISM AND CONTROL MEASURES.

Sr. No.



1A Transportation of ore and O/B -Use of machinery COLLISION & RUNOVER

1A.1.1(B&C) (i) Narrow road width

1A.1.1B&C(i) a-1 Haul road design to be planned for separation of empty and loaded vehicles where-ever possible

Being implemented.

b-1 Optimum road width as per condition of permission to be provided

Width of the haul road is as per the permission except at a few places

b-2 Whenever provision of optimum road width is not possible for some reason, traffic control at the wider place to be done by flag and by light beyond day light hours.

At narrow places, guards with red flag are provided and no work is being done in opencast beyond day light hours.



c-1 Dumping area should be planned to have sufficient space to accommodate more number of dumpers.

No crowding observed as there is sufficient space in the dumping area.

c-2 More number of dumping zone /area to be provided in case of increase in population of ME

d-1 Executive and supervisor should work to ensure speed restriction as specified in the specimen code of traffic rules

Speed restriction is being ensured

d-2 The speed restriction shall be complied with by the operator (additional)

e-1 Only competent operator shall be appointed.

Being ensured.

e-2 Regular training and retraining of the operator to be continued.

Training and re-training is being done as per the statute.

1A.2 1B&C (ii) Overloading extending breaking distance

1A.2.1 B&C (ii) a-1 Guidelines/instruction to be issued to shovel & dumper operator restricting load in terms of number full buckets.

As informed by the management, verbal instructions are given by the supervisor present at the site.

b-1 Load indicator should be provided in the dumper.

Not provided

b-2 The dumper operator shall give horn as soon as the load indicator indicates the maximum permissible load.

c-1 Operators of both shovel & Dumper to be explained, the implication of overloading and how to ensure correct loading of dumper.

Verbal instructions are being given.

1A.3.1 (B&C) (iii) Working standing overtaking and right of way.

3.1.1B&C (iii) a-1 The Management shall frame the operating procedures in Hindi based on specimen Traffic Rules and circulate.

SOP framed and circulated

1A.3.1(B&C) (iii) Working standing over taking and right of way.

a-2 The operators shall be explained of the operating procedures and implication thereof during the training period.

As informed by the management, the operators are being explained during training period.

a-3 The operators shall comply with the Safe Operating procedures to

Being complied



ensure safety

1A.4.1 (B&C) (iv) Interaction between light ME and heavy ME (light ME playing for transportation of employees and supervision of executives)

1A.4.1(B&C) (iv) a-1 Traffic Rules for movement of light vehicles within the mining active areas framed covering all issues under control and to be circulated in HINDI.

Traffic rules for movement of light vehicles within the mining area have not been framed. As informed by the management only valid driving license holders are allowed to drive the vehicle inside the mine.

1A.4.1 (B&C) (iv) Interaction between light ME and heavy ME (Light ME playing for transportation of employees and supervision of executives.

a-2 The operators of light vehicle shall be trained on the new traffic rules framed and their competencies to be assessed after training.

1A.5.1 (B&C) (V) Me movement in congested area (around built –up areas working faces and other areas)

1A.5.1(B&C)V) a-1 Revised Code of Traffic Rules to be implemented.

Implemented

a-2 Operators are to be trained on revised traffic rules and their competencies to be assessed after every training.

1A.6.1 (B&C) (vi) ME hitting overhead power line/cable tower

1A.6.1 (B&C) (vi) a-1 Code of practice in use of electricity to be framed considering the issues mentioned under controls

COP in use of electricity framed and circulated.

Table No. 18C: Risk Management Action Plan For Prevention of Accident during installation, repair and maintenance of Transportation machinery

Sr. No. Sub-activity Mechanism Recommended Action vide earlier study report

Status as observed by Kratin

1. Installation, repair and maintenance of transportation machinery – Dumper, Tipper, Truck Major repair outsource One shift

1.1.1 A (i) Disintegration of moving parts, flying/falling off equipment during grinding/installation/trial run etc.

a-1 Rotating parts shall be guarded/fenced off and maintained.

Guards and fences provided

b-1 Code of safe practice on good housekeeping shall be framed in Hindi based on specimen copy enclosed and displayed in workshop.

Framed & displayed

c-1 In addition to provision of guard/ fence the area to be



operation. Installation, repair and maintenance of transportation machinery – Tipper, Truck Major repair outsourced Two shifts work in workshop/garage outside.

kept as restricted entry for unauthorized person

Implemented

d-1 A schedule to be framed and implemented. ( Preventive maintenance)

e-1 PPE shall be provided and regular use to be enforced.

PPEs being provided and used

1.2.1B (i) Injury by impact of parts falling off machine or collapse of body/structure/fall on machine

1.2.1.B(i) a-1 A schedule of maintenance to be framed and followed.

Schedule framed and being followed.

b-1 Work area surroundings including equipment operating at height (crane) to be checked before start of maintenance.

Being checked.

1.2.1.C (i) Incorrect housekeeping- tripping over loose object, hit by projected material, slipping on oily floor

1.2.1.C(i) a-1 Good housekeeping shall be planned, codes framed based on specimen copy and implemented to keep the area free of obstructions and oily floor and good ventilation.

House –keeping is good.

1.2.1.D (i) Caught in between moving parts or moving and stationary parts

1.2.1.D(i) a-1 Sufficient space to be provided around the place for maintenance.

No constraint of space around the place of maintenance

b-1 Effective fencing to be provided against moving machinery situated near the place of maintenance.

Provided.

1.2.1.E (i) Fire from spilled oil or grease etc.

1.2.1.E(i) a-1 Safe code of practice to be framed in Hindi based on specimen copy enclosed – to keep the workshop free from unused mobile oil/grease etc.

SCOP framed

b-1 Fire extinguishers of appropriate type to be provided and maintained.

Fire extinguishers of appropriate type provided and maintained.

c-1 Fire detection device to be provided at appropriate places to give warning on early detection.

Not provided.

(a) Heavy machine parts, lifting by machines

1.2.1F(i) a-1 In case of handling heavy machine parts, lifting machine (crane) to be used.

OHT Crane is provided for lifting heavy machine parts.

b-2 Code of practice for use of COP not framed in



lifting machine (crane) to be framed in Hindi based on specimen enclosed.

Hindi

1.2.1.G (i) Slippage of tools -Incorrect use of tools -Use of incorrect tools.

1.2.1.G(i) a-1 The Foreman and mechanic to be trained in correct use of tools

Training is being given as required under the statute.

b-1 Tools of appropriate type to be maintained in locked rack/almirah and each rack/almirah to be placed in charge of a mechanic to guard against pilferage/misplacement of tools.

Implemented

c-1 PPE to be provided and regular use to be ensured.

PPE provided but regular use needs to be ensured.

1.2.1.H (i) Fitting/re-fitting/inflating of tyres.

1.2.1.H(i) a-1 Correct procedure to be laid down in Hindi

Not implemented

b-1 Correct pressure of different types of tyres to be maintained and gadget with automatic cut-off to be installed and maintained.

Being implemented

c-1 Suitable sized cages to be provided for use for different size tyres.

Table No. 18D: Risk Management Action Plan For operation of Non-Transportation machinery



1.0 1.1 Loading of ore and OB by Excavator, Drilling by drills, Haul road preparation & Dump preparation by Dozers, Scrapers, Graders etc. One shift operation

1.1.1. ROLLOVER, COLLISION, RUNOVER (i) Brake failure, steering failure, other control switches failure etc.

1.1.1 (A to C) (i) a-1 Action on formulation of operational procedures, responsibility and accountability for compliance of safe operational procedures, compliance of schedule of different type of maintenance and operator’s competence and fitness to be prepared in Hindi on the lines of action plan prepared for dumper and different specimen code of practices enclosed.

SOP prepared in Hindi.

1.1.1.(ii) Reversing Dozer, Grader, Scrapper

4.1.1 (A-C)(ii) a-1 The action plan with good maintenance, reversing



procedures, restriction on speed, ensured clear view, operator’s competence etc. to be framed in Hindi based on specimen code of procedures enclosed.

1.1.1.(iii) Adequate maintenance of electrical controls and compliance of shut-down procedures.

1.1.1.(iii) a-1 The action plan to be prepared and schedule of day-to-day maintenance to be framed and executed as per specimen code enclosed.

Maintenance schedule prepared.

1.1.1.(iv) Fall from height/machine.

1.1.1. a-1 The person concerned to be careful and attentive during work.

Persons are careful and attentive during work

b-1 Guard/fencing in & around the entry to cabin to prevent inadvertent fall to be maintained.

Guard/fencing provided

c-1 In case of work at risky place on machine PPE to be provided and use ensured.

PPE provided and being used.

1.1.1.(i) Fall by slipping/slippery floor/cabin – Poor housekeeping.

1.1.1.(i) a-1 The machine cabin and surrounding to be kept clean of oil, grease and any obstruction.

House-keeping is satisfactory

b-1 The person to be careful and attentive

1.1.1.(i) Electrical fault/shut down procedures lapses.

-do-

Shut down procedure is Being followed.

1.1.1. (i) Drill rod change – irregular

1.1.1.(i) a-1 Provision & use of PPE to be ensured.

Being ensured.

b-1 Diesel filling while the engine is off & cool to be ensured.

c-1 Wet drilling provision to be provided & maintained.

Implemented

d-1 Fire extinguisher to be provided & maintained.

Provided.



Table No. 18E: Risk Management Action Plan For installation, repair and maintenance of Non-Transportation machinery



1.0 1.1 Working in proximity to machinery (Other than WTTM) Major repair outsource

1.2.1 (i) Maintenance of major components- changing/maintaining different ropes, brake system, steering etc.

1.2.1.(i) a-1 Code of practice for installation, repair and maintenance.

COP framed

b-1 Schedule of maintenance based on brake down analysis and condition based monitoring (CBM) when introduced.

Maintenance schedule prepared

c-1 Computerized information on all activities at different places.

Computerised information is available.

d-1 Code of practice on material handling and good housekeeping. -Action plan on the above based on specimen code of practices enclosed to be made in Hindi and circulated.

Code of practice framed and circulated.

1.2.1. (i) Person falling from machine

Action plan on code of procedures for installation, repair & maintenance and on all other controls to be prepared in Hindi based on specimen enclosed and on the lines as documented above.

1.2.1. (i) Caught in between moving parts.

1.2.1 Incorrect housekeeping

1.2.1 (i) Fire in spilled oil, grease

1.2.1. (ii) Person hit by machine swing – during maintenance on changing of ropes etc.

Safe code of procedures of rope changing etc. based on specimen enclosed to be documented in Hindi and circulated.

Presently only hydraulic shovels are used hence such situation does’nt arise.

1.2.1. (iii) Slippage of tools.

-do- SOP framed.



Table No. 19:Risk Management Action Plan For Prevention Of Accident due to Ore Processing at OCF


Kratin

1.0 Dump Mining, Boulder Mining

1.1 Failure of bench/ collapse of sides/ collapse of overhang

a) Regular formation of benches with reqd. width and height to be ensured. b) Dressing by the machine to be introduced c) Use of machine for loading to be introduced d) Formation of overhang in boulder mining to be avoided

Implemented

2.0 Breaking & sorting -Big lumpy ore Medium size ore small size ore General shift operation

2.1.1A Hit by flying pieces.

2.1.1A a-1 Provide metal circular ring around the small & medium size ore.

Not implemented.

b-1 Helmets, shoes goggles leg –guards are to be provided.

Provided

b-2 Use of PPE to be ensured

Being ensured.

b-3 PPE to be used. Being used. b-4 Create awareness for use of PPE

Posters displayed at conspicuous places.

c-1 Breaking should be mechanized.

Not implemented

2.1.2 Caught Between hammer & stone /ore.

2.1.2 a-1 The workers to be attentive while on the job.

Workers are attentive.

b-1 Correct size hammer & hand gloves to be provided and used.

Gloves provided but use needs to be enforced.

c-1 Correct procedure of breaking to be followed

Being followed.

d-1 Machine breaking of ore to be introduced.

Implemented.

2.1.3 Hit by rolling stones.

2.1.3 a-1 Workers not to be allowed to work at the foot of high stack.

Being ensured.

b-1 height to be reduced by use of spade. c-1 PPE to be provided. Provided. d-1 Use of shoes and shin-guards to be ensured.

Safety boots are used; Use of shin guard needs to be enforced.

e-1 Height of Dump to be reduced by machine.

Implemented.

Ore Stacking/loading

3.1.1 Fall on ground by slipping & Tripping

3.1.1 a-1 Worker to be careful and attentive during work.


a-2 Avoid travelling in steep /slippery place.

Being ensured.



3.1.2Hit by fall of ore pieces due to over loading during carrying.

3.1.2 a-1 The workers not be allowed overloading.

Overloading is not allowed.

3.1.3 Hit by fall of ore on body during loading stacking.

b-1 Workers to be careful and attentive during moving with load.


Table No. 20A Risk Management Action Plan for prevention of Accident due to fall of persons from height- Surface operations

Sr.no. Sub-Activity Mechanism Action Plan Status as observed by Kratin

1.0 1.1 Construction installation erection maintenance of plant OVERHEAD Transmission line, Ore processing at OCF, Dump Mining, Boulder mining etc. One shift work

1.1.1A (i) Failure to provide and ensure use of personal safety equipment –code of Practice.

1.1.1A(i) a-1 Approved PPE to be provided and maintained.

Approved type PPEs are provided and maintained.

a-2 Use of PPE in operation at height and in some other operation likely to fall into depth to be ensured.

Being ensured.

a-3 Audit for compliance of correct use to be done.

Being done.

b-1 The person to be trained in use and maintenance of PPE.

Persons have been trained in the use of PPEs.

1.1.1B (i) Fall by slipping/ loosing balance.

1.1.1B(i) a-1 Everyone to be careful and attentive to avoid any work on the edge not provided with fence/guard.

Persons are careful and attentive.

a-2 Code of practice for safe work at height prepared in HINDI to be circulated.

-----------

1.1.1C (i) Failure of ladders /walkway stairs

b-1 Use of PPE to be made regular practice. c-1 Safety Net to be provided beneath the place of work to be decided by the management whenever the height of work place exceeds 5M.

Being used as and when required. Not implemented.

1.1.1C(i) a-1 Old ladders/walk way/structures to be

Not tested.



inspected, tested with 50% more load than designed capacity at regular interval for strength /stability.

b-1 Ladders of adequate strength to be placed on stable ground and to have safe inclination

Ladders of adequate strength are placed on stable ground at an inclination not exceeding 800.

b-2 Partially completed loosely placed stair-way walk way not to be used.

Being ensured.

1.1.1D (i) Poor supervision control and management

1.1.1D(i) a-1 Permit to work system may be introduced during work at height.

Introduced.

a-2 Compliance of safe code of practice during work at height.

Being complied.

Table No. 20B: Risk Management Action Plan For control of accidents due to fall on level ground

and hit by objects/material

S.No. Sub-Activity Mechanism Action Plan Status as observed

by Kratin

1.0 1.1 Installation

Operation, repair &

maintenance.

1.1.1A

(i) Lack of

awareness on

code of safe practice

of different

activities/

operations in the

mine

1.1.1A(i)

a-1 Guidelines and safe

procedure of work of no.

of important activities

are already framed. But

codes on remaining

activities to be framed

and circulated.

COP for different

activities to be

framed in Hindi

and circulated.

b-1 Regular training as a

routine to be given to all

regular and contractual

workers at the site.

Training as per the

statute is being

given to both the

departmental as

well as contractual

workers.

1.1.1B

(i) Lack of

awareness on code

of good

housekeeping

1.1.1B(i)

a-1 The places/work

sites to be kept free of

water, obstruction and

provided with steps in

Being

implemented.



case of travel in steep

road.

a-2 Safe code of

practice on good

housekeeping already

available to be

implemented.

Being

implemented.

1.1.1B

(ii) Lack of

awareness on safe

code of material

handling

1.1.1b(ii)

a-1 Safe code of practice

for manual and machine

handling to be circulated

and implemented.

SCOP to be framed

in Hindi and

circulated.

b-1 Workers to be

provided with PPE and

its use to be ensured.

PPE provided and

use being ensured.

1.1.1C

(i) Fall of material

/object including

rolling

Object

1.1.1C(i)

a-1 Provision and use of

PPE to be ensured.

Being ensured.

b-1 Safe code /

guidelines to carry out

each and individual work

to be prepared and

workers to be trained.

Implemented

c-1 Risk assessment for

new job to be done as a

routine.

In process.

1.1

Installation,

Operation, repair &

maintenance General

Shift Operations.

1.1.1D

(i) Fall by slipping

tripping

1.1.1D(i)

a-1 The person to be

careful and attentive

during travel movement

and taken adequate

precaution in his job

whenever required.

Personnel are

careful, attentive

and take

precautions during

movement. a-2 He should avoid

traveling in steep and

slippery road steps etc.

with speed.

a-3 Steps and handle to be provided in steep / slippery roadway.

Provided.

Table no. 22: Risk Management Action Plan to prevent accidents due to use of electricity

Sr.No. Sub-Activity Mechanism Action Plan Status as observed

by Kratin

2 2.1 2.1.1 Shut down procedure as Shut down



Use of Elect. Equipment - Shutdown/Chargin

g of power line, changing of Bulb/Tube fittings on surface

- Malfunctioning of Elect. Equipment.

- Two shift operation, During Monsoon 3 shift operation.

A. failure of fuse and earthing system – Contact with OH power lines.

framed shall be complied with.

procedure framed and complied.

Engineer shall issue guidelines for provision and maintenance of earthing and general precautions in earthing.

Being followed.

The Engineer shall ensure that EL protection is provided as required under IER.

Ensured The Engineer to ensure provision of mechanical locking and issue necessary instructions.

2.1.1 B. Non-compliance of shutdown procedures – Direct contact.

The engineer should ensure compliance of Shut Down Procedure and maintenance of records.

Being ensured

2.1.1 C. Non-compliance of permit to work system – Direct contact.

i) Engineer to ensure compliance of the provision of electrical safety device as per IER- 1956. ii) Instruction to be issued by the engineer for use of PPE. iii) Strict supervision to ensure compliance.

Regular follow up is being done

2.1.1 D. Failure in ensuring maintenance of safety protective devices in the transmission system – Defective Equipment.

2.1.1 E. Failure to use safety equipment (PPE) during work.

i) Competent electrician/supervisor to be authorized for the job. ii) Duties and responsibilities and jurisdiction as specified in the authorization letter to be complied with. iii) Code of practice on Good Housekeeping as enclosed to be followed. iv) Training and re-training of electricians and supervisors on

Fire extinguishers at all substations provided however this being a regular activity, to be ensured every time. Implemented.

2.1.1

F. Fire in electrical

installation



precautions against fire in electrical installations and use proper type of fire extinguishers in case of emergency.

Table No. 23: Risk Management Action Plan for prevention of accident due to use of explosives – O/C Operation

Sr. No.



1 Blasting by use of explosives. Blasting in 1st shift.

1.1A (i) Use of explosive of unapproved type beyond shelf life

1.1A(i) a-1 Slurry & emulsion type explosive within shelf life to be used.

At the magazine First In First Out system is practiced.

2.1.1B (i) Pre-detonation during transport of explosives.

2.1.1B(i) a-1 Approved type of vehicles to be used for transportation of explosives.

Licensed explosive van is used for transport of explosives.

b-1 The statutory & recommendatory provisions for transport and handling of explosive shall be complied with.

Being Complied

2.1.1C (i) Entry of personnel within danger zone due to inadequate warning to all concerned.

2.1.1C(i) a-1 Siren with wide area-coverage to be provided and maintained.

Being complied

b-1 Posting & withdrawal of Guards to be regulated as per CARD system in force.

Guards are posted but CARD system not followed.

c-1 Blasting to be done during fixed hours and this should be circulated to all.

Circulated and blasting is being done during the day at fixed time only.

1.1D (i) Inadequate precautions in taking shelter/non-provision of approved type of blasting shelter.

1.1D(i) a-1 Blasting gang to take shelter at appropriate blasting shelter.

Blasting crew takes shelter at the appropriate blasting shelter.

a-2 Sufficient number of portable blasting shelter to be provided in mining area.

Adequate number of blasting shelters has been provided.

1.1E (i) Sleeping of holes – non-compliance of safety precautions.

1.1E(i) a-1 Precautions stipulated in the permission for sleeping holes to be complied with.

Permission for Sleeping of the holes not obtained and holes are not allowed to sleep over.



1.1F (i)Unsatisfactory control and management on use of explosives.

1.1F(i) a-1 Efficient control and management on use of explosive to be developed and maintained.

Explosive charge per hole/blast is within permissible quantity.

TABLE NO. 24A : Risk Management Action Plan for Control of Hazards due to Manganese dust:

S.No.

Sub-Activity Mechanism Recommended Action vide earlier study report


1.0 1.1 Exposure to respirable dust generated by drill machine operation and wind- Causing Pneumoconiosis (Silicosis) and manganese poisoning by long exposure. Dust survey was not as per DG’s Circular no. 1 of 2004.

1.1.1 (i) Control measures for prevention of dust – Generation, detection, monitoring – Control & suppression – Unsatisfactory.

1.1.1(i) a-1 Air-borne dust concentration assessment in different operations to be made by gravimetric dust sampler.

Fixed point dust sampling is not done at workplace (underground) for different operations. Only Ambient air monitoring is being done on surface. Fugitive dust monitoring on surface (haul roads, transport roads, Siding etc.) is not done.

a-2 Assessment of dust dose and the exposure profile to be made by use of personal dust sampler once.

Personal dust sampling (for respirable dust & quartz content) is done by external accredited agency every 6 months, on workers engaged in mucking & drilling operation in underground;

a-3 Manager’s scheme for sampling of Air-borne dust shall be prepared and implemented.

Manager’s scheme for sampling of Air-borne dust has not been prepared and implemented. The ambient air monitoring is done at 4 stations quarterly by an accredited external agency. Personal dust monitoring of underground worker is done in every 6 months by another accredited external agency. There is no in-house facility for air/dust monitoring at the mine.

a-4 The dust sampling and monitoring team members to be trained.

b-1 Based on the report of air-borne dust monitoring, areas of high dust generation to be identified and control measures for liberation and accumulation as provided in the law shall be taken – No scheme executed. -Provision of dust extractor-not provided in drill.

Only ambient dust monitoring is done on surface. Monitoring of fugitive dust generation at UG mine faces & on surface is not done. As such, areas of high dust generation have not been identified. Dust Control Measures undertaken: - Water injection system fitted in

underground drill machines; - UG faces, side walls are wetted



-Use of wet drilling-provided.

with water during drilling & during blasting & mucking;

- 1 no. water tanker 5 KL cap. is deployed for dust suppression on ore transport roads & Siding. But it was found inadequate as all roads without bitumen top.

- Plantation has been done for dust absorption but it is barren around siding.

c-1 Measures to be taken for Dust Suppression near about the source by application of water: - Only wet drilling

provided.

d-1 For ensuring adequate treatment of air-borne dust system at i.e. Sampling shall be carried out , dust to be tested and analysed as provided in the statute. All records to be maintained:

Air-borne dust monitoring is done on surface (ambient air). No fixed-point dust monitoring is done in underground. Personal dust profile of UG worker is monitored. Fugitive dust monitoring on surface (roads, Siding) is not done. On the basis of analysis of ambient air quality, Dust Control Measures are undertaken. All records are maintained related to air quality monitoring and quarterly reports are submitted to MOEF & MPCB.

e-1 Where dust cannot be sufficiently suppressed to stipulated limits, every person exposed to such high concentration of dust shall be provided with suitable dust respirator – such assessment was not done. e-2 The personal protective equipment shall be cleaned disinfected and maintained in proper working order – not adequate measures taken.

It has been informed by the management that dust masks have been provided to the workers. However, no worker was found wearing dust mask while working in dusty conditions e.g. loading/unloading area (siding), ore transport road etc. It could not be assessed whether PPEs are maintained properly.

f-1 Training of workers concerned in the need for and correct use of respirators shall be arranged - Execution not adequate.

Formal Training is not given to workers regarding the need for as well as correct use of respirators.

1.1.1 (ii) Excessive respirable dust - Exposure/

inhalation

1.1.1 (ii) a-1 Every person seeking employment in a mine shall be medically examined before employment.

Pre-employment Health assessment is done in the form of Initial medical Examination (IME) for all employees.



- Irregular medical examination

(iii) Drinking of waste/ nullah water with dissolved mineral.

b-1 Periodic medical examination of every person employed in the mine at intervals not more than five years or earlier shall be carried out.

Periodic Health assessment of workers is done in the form of PME once in every 5 years. PME of Contractual workers has not been done till date; PME of workers exposed to dusty conditions is also done once in 5 years instead of stipulated 6 months. Borewell water is supplied as drinking water to employees at workplace and at residential colony. But its Potability is not tested as per drinking water standard IS:10500. As per medical officer of occupational health centre, no case of manganese poisoning has been reported during PME.

c-1 During the medical examination if any worker is found to be in Group-IIa&IIb, he shall be deployed in less dusty area in consultation with DGMS.

Being complied.

d-1 In case any worker is found to be unfit for work he shall be sent for evaluation by disability Board and subsequent action.

TABLE NO. 24B : Risk Management Action Plan for Control of Hazards due to Noise

S.No.

Sub-Activity Mechanism Recommended Action vide earlier study report


1.2 Mining operations – Exposure to Noise emitted by Machines. Noise level in drill machine is more than 90 dB(A) but the duration of noise was less than 8

1.2.1 (i) Control Measures for prevention of noise emission and suppression/minimization - Unsatisfactory

1.2.1(i) a-1 Design & specification to restrict the noise level between 85 dB(A) and 90 dB(A) to be standardised.

Being followed in case of procurement of new machine only. Not followed in case of existing machinery. As per quarterly noise monitoring report, the noise level recorded at Jack Hammer Drill (underground) in Dec. 2014 was 103.80 dB(A), in Sept’14 101.40 dB(A) & in July’14 94.80 dB(A). The noise level at Ventilation Fan house was recorded as 87.30 dB(A) & 86.40 dB(A) in Sept’14 & Dec’14. In spite of this high noise level, no

1.2.1 (i) b-1 Equipment selection criteria as well as its assessment procedures to be standardised and to be furnished to the manufacturers/suppliers of the machines.



hours continuous and the time weighted average is likely to be lower than 90 dB(A)

effort has been made to control noise level at drill machine &ventilation fan.

1.2.1 (i) c-1 Equipment shall be maintained efficiently to control noise emission.

Not satisfactory from noise control point of view.

1.2.1(i) d-1 Regular noise level survey and assessment of exposure of workmen to be carried out. Last noise level survey was carried out & some places identified. New survey to identify new sites to be done immediately.

Quarterly Noise level survey is done near mine Pit, haul road, Ventilation Fan & jack hammer drill. Noise mapping not done to identify all high noise zones. Assessment of exposure of workmen by noise dosimetry not done.

d-2 Noisy Zones shall be established from Noise level survey and shown on ‘Noise Map’. Noise survey was of casual nature and was not serving the desired objective.

Regular noise level survey (Fortnightly) is not done. Noise mapping has not been done as on date. No sound level meter is available with the mine. From Quarterly noise level survey, it is observed that jack hammer drill & ventilation fan are major sources of noise.

1.2.1(i) e-1 Noise Control at Source in new machinery same as at sl. No. a, b & c above.

No conscious efforts are being made to control noise emission in use of existing machinery. It is informed that during procurement of new machinery criteria for low noise are being taken into consideration.

e-2 Noise control of existing installation.

1.2.1(i)(f) f-1 Noise source shall be relocated so as to reduce the exposure to more number of people.

Not being considered feasible.

1.2.1(i)(g) g-1 The noise shall be dampened/ quietened by layers or mounting of soft or elastic material.

Not being done.

1.2.1(i)(h) h-1 The noise level warning sign shall be displayed wherefrom the noise level exceeds 85 dB(A).

Noise level warning sign not displayed at locations where noise level exceeded 85 dB(A).



h-2 Physical barriers shall be provided wherefrom the noise level exceeds 90 dB(A).

Not provided in case of jack hammer drill where noise level exceeds 90 dB(A).

1.2.1(i) i-1 The noisy machine shall be enclosed with cover if practicable; or,

There is no enclosure for operators of jack hammer drill at underground. The ventilation Fan is housed in a building but the operator does not have a separate enclosure.

i-2 The operator shall work inside a noise-proof enclosure; or,

i-3 Where more number of people are exposed to noise, the people shall be isolated from the source by providing an acoustic control enclosure. If all these measures are not practicable, then control at sl. No. (j) below

1.2.1(j j-1 The machine may be operated by remote control system.

Found not feasible in the given circumstances.

1.2.1(k) k-1 Periodic noise level survey shall be conducted to assess the efficacy of control measures.

Noise level monitoring is done quarterly instead of fortnightly. No specific noise control measure has been taken at workplace.

1.2.1 (II) Exposure to Excessive Noise – Monitoring of loss/impairment – hearing protection – unsatisfactory. Hearing protection accepted as a first line of action where noise level is likely to be more

1.2.1(ii)1(a a-1 Assessment of residual noise exposure level after introduction of noise control measures shall be done.

No specific noise control measure has been taken at workplace. Noise level monitoring is done quarterly instead of fortnightly as per statute.

a-2 Suitable hearing protector shall be selected & provided in designated areas.

Ear Muffs provided to workers but nowhere were they found to be using the same. Even at jack hammer drill underground, where noise level is recorded above 100 dB(A), the operator was not wearing PPE.

a-3 Workers shall be trained to ensure where & when the protector to be used.

Not being followed satisfactorily.

a-4 Proper record keeping on issue & re-issue shall be introduced. a-5 Adequate supervision to ensure proper use to be exercised.



a-6 The protectors shall be maintained hygienically.

1.2.1 (iii) Monitoring of Hearing Loss/Impairment – Audiometric & Medical Surveillance - unsatisfactory

1.2.1(iii) a-1 Audiometric testing of workforce before entry to the job and also those who are exposed to noise level exceeding 90 dB(A) shall be done.

Audiometric Test of workers is done periodically in course of IME & PME. High noise areas have not been identified, and specific medical surveillance of workers exposed to high noise level is not carried out. The necessary precautions before carrying out audiometric examination are being taken.

a-2 Medical surveillance & evaluation to assess the effectiveness of Noise Control And Hearing Conservation Programme shall be carried out. a-3 The necessary precautions before carrying out audiometric examination shall be taken.



Chapter - III

Safety & Health Management Plan

A safety management system should set the culture, framework and action necessary

to ensure that mining operations are carried out safely. Safety & Health management Plan

has been prepared through the following seven steps:

1) Identification of the hazards.

2) Specifying the mechanism contributing the hazard.

3) Measuring the risk involved by taking into account ‘Consequences, Exposure &

Probability’.

4) Calculating the Risk Rating (Risk Score) of each identified risk.

5) Specifying controls for each mechanism.

6) Indicating the person(s) responsible for implementing the controls, and

7) Suggesting time frame/schedule for completion of task.

Objectives:

Reviewing Health and safety policy of MOIL Ltd. in general and Munsar mine in

particular.

Defining the roles and responsibilities at all levels in the organization.

Review of formation/functioning of Safety committee and defining its role.

Selecting suitable methods to identify and control high risks.

Carrying out forward program to ensure actions to control hazards.

Emergency preparedness to cope with a hazard if it should occur.

Monitoring process for all identified hazards with or without residual risks.

Identification of trigger points and their consequences.

Defining safety clearance of new equipments, work methods and materials used.

Accident statistics, collection, analysis and actions.

Reporting and record keeping requirements.

Auditing and review process.

The roles of the key personnel (owner, agent, manager, safety officer, Engineer,

supervisor, workmen’ inspector, trade union representative, mechanic, operator, worker,

contractor etc.) have been spelt out in the Safety & Health management Plan.

In the process of management of safety in the mine, all mine personnel have different

roles to play but still have the same objectives and share a duty of care to:

Provide a safe place of work;

Provide proper equipments and facilities;

Have and follow a safe system of work;

Have competent staff/employees;

Look after fellow workers;

Take appropriate precautions (e.g. use of PPEs);

Raise safety issues and continuously improve;

Have appropriate emergency procedures.



During formulation of strategies to ensure the health & safety of Munsar mine and its

employees, following points have been considered:-

a) Compliance to various applicable statutes as a pre-requisite.

b) Creation of safety culture in the organization for prevention of any accidents.

Based on Risk assessment, the Safety & Health Management Plan has been prepared on:

Management System; and,

Critical areas of operations.

Following established methods of risk control have been considered while preparing

this Risk Management Plan:

Elimination

Substitution

Separation

Administration

Training

Use of PPEs

Definitions:

Hazard: Source of potential harm, injury or loss.

Risk: Combination of a likelihood of specific unwanted event and

the potential consequences if it occurs.

Risk Assessment: A process that involves measurement of risk to determine

priorities and to enable identification of appropriate level of

risk treatment (used also to describe the overall process of risk

management).

Risk Control: Implementation of strategies to prevent or control hazards.

Risk Rating: The category or level of risk assigned following risk assessment

(e.g. High, Medium, Low etc.).

Risk Management: Overall description of the steps taken to manage risk, by

identifying hazards and implementing controls in the

workplace.

Hazard Identification and Risk Assessment: Risk Assessment has been conducted to identify any hazards that could influence the

safety and health of the mine and the workers at the Mine.

Hazard management plan has been drawn up for all the hazards that pose a potential

chance of fatalities and cannot be fully controlled. Based on Risk Assessment, Safety &

Health Management Plan has been prepared for Munsar Mine of MOIL Ltd. Entire

procedure has been carried out as suggested vide DGMS Cir. 13 of 2002.

Risk assessment process: Team:

For conducting Risk Assessment, Kratin’s team comprising Sri S.N. Katiyar, President &

CEO, Sri A.C.Ray, Advisor (Environment), Sri S.V. Joshi, G.M. (Safety & Training), Sri C. P.



Varma (E&M) and Sri S. Ramtekkar, Geologist of Kratin Solutions Pvt. Ltd. visited Munsar

Mine of MOIL Ltd. from 27thto28thApril, 2015.

During mine visit the team inspected underground and opencast dump workings,

loading & unloading area, electrical Sub-station, manual ore breaking & sizing area, surface

& underground infrastructure, and, had discussions with the Mine Manager, Safety Officer,

Surveyor, Engineer, Workmen’ Inspectors and other supervisory staff of Munsar Mine

regarding the existing permissions and practices being followed. Relevant documents and

copies of various DGMS permissions were also studied as a part of the Risk Assessment and

preparation of Safety & Health Management Plan.

Work flow diagram of Risk Assessment Session:

Methodology of Risk Assessment:

The methodology of Risk Assessment included study and analysis of the existing-

1) Procedures;

2) Maintenance standards;

3) Supervision quality;

4) Management strategy.

Inspection of the mine:

During the inspection of the mine from 27thto 28th April 2015, following places were

inspected:

Vertical shaft , incline and underground working at 70’L;

Winder House;

Explosive magazine

Workshop



Vibrating screen at Ch.1100

Sand Stowing Plant;

Compressor house;

Ventilation Fan house;

220’ L Dump mining area;

Plantation area;

Mine office;

Substation.

Hazard identification and Risk Assessment Mining activities involve hazards associated with support, ventilation, pumping, drilling,

blasting & extraction of rock and mineral, handling, deployment of HEMM, transport and

dispatch of ore. Maintaining safety of the mine & the persons employed therein as per

statutory provisions, is a challenging task which requires continued commitment of the

management & employees ensuring compliance of safety legislations, guidelines and

circulars issued by various statutory authorities.

Formulation and implementation of safety management system ensures that all risks

are identified and critical risks are controlled for long term health & safety of the employees

and surrounding population with minimum damage to the environment.

The hazard identification and risk assessment process for Munsar Mine involved the

following activities:

Identification of hazards that could influence the health & safety of the mine workers.

Assessment of risks posed by these hazards based on severity, consequence and probability of occurrence.

Identification of those exposed to risk and the risk level (exposure) due to different aspects of mining activities.

Determination of measures necessary for: Eliminating the recorded risks; Controlling the risks at source; Minimizing /mitigating the risks; and,

In case the risk remains, To formulate a program for monitoring the risk to which employees may be

exposed. Provide Personal Protective Equipment (PPE).

Hazard identification:

Hazard identification has been done through work process evaluation, study of accident

statistics, consultation with the employees and previous experience of accidents and near

miss incidents at Munsar Mine. The identified hazards were noted, tabulated and risk

ranking was done considering both the likelihood and the potential consequences. The

assessed risks are being described below:

i) Improper Strata Control:

Scientific study for strata control was carried out by CMRI (now CIMFR). However, no

fresh scientific study/review of earlier study has been done on Strata Control.



Conventional Prop and Chock support system is used in underground stopes and the

development headings are supported by roof bolts. For speedy filling of underground void,

hydraulic sand stowing is being adopted.


Systematic Support Rules (SSR) have been framed and implemented. Assessment of risk

due to improper strata control has been done considering the following possibilities:

Failure to identify bad roof;

Improper loose dressing;

Improper supervision;

Lack of proper organisation for erecting supports;

Poor workmanship;

Inadequate support design;

Poor quality of support materials;

Breakage of scaling bars & tools etc.;

Lack of proper system of Handing-over charge between statutory supervisors during shift changeover;

Loose dressing at faces where height is more than 3 m;

Loose dressing in travelling roadways; The efficacy of the bolting system at Munsar mine needs to be closely monitored ensuring implementation of the recommendations of DGMS Cir. 11 of 2009 and Cir. No. 3 of 2010 as follows:

Physical examination is conducted but Tensile Test of the Roof Bolt Assembly shall also be conducted for every batch of Roof Bolts & its accessories received at the mine and recorded.

Length of the Roof Bolt shall not be more than the designed length + 5mm.

Diameter of the Roof Bolt shall not be more than the designed diameter + 4% by mass as specified under IS 1786 – 2008 or as per the standard given in BS 7861 (Part-1) 2008.

Straightness: The roof Bolt shall be straight without any joint, welding, deviation or deflection. However if the deflection or deviation cannot be avoided due to practical reasons, it shall not be more than + 0.1 % per meter length of the bolt.

The Rib of the Roof Bolt shall be as per design of the rib with an objective to maximize the surface area without reducing the core diameter of the roof bolt and having maximum grip with the grout. However the height of the rib shall be kept within the standard prescribed in IS 1786 – 2008 or BS 7861 (Part 1) 1996 or latest revision thereof.

Steel for the Roof Bolt: The Yield Stress, Tensile Strength and % elongation steel Grade shall be maintained as per the IS 1786 and IS 13920.

However the minimum load bearing capacity (Anchorage Load) of the roof bolt

shall be 160 kN.

The Roof Bolt Assembly shall be subjected to Tensile Test and should not fail up to 16 Tonnes load.



The Roof Bolts and its components or parts shall be subjected to Accelerated Weathering Test in mine water condition for 20 days. No deterioration should occur on the Assembly.

In order to check the composition and required parameters during manufacture, it shall be required that the random sampling be done @ of 2 roof bolts per 1000 pieces of roof bolts and its accessories manufactured in a batch which shall be subjected to the required set of tests as prescribed above and the data shall be recorded and signed by the persons carrying out the test.

In case the Roof Bolts or any of its accessories fail to pass the required tests, that batch or lot of the manufacture shall not be used in the mine and intimation thereof shall be sent to the manufacturer and recorded.

Bearing Plate- The bearing plate of the roof bolt shall be Dome Washer Plate of dimension 150 x 150 x 8 (minimum) mm with compatible central hole of required size and angled side to accommodate the conical seat and nut.

The minimum load at which the Domed Washer Plate will become flat should be at least 14 Tonnes.

ii) Use of Machinery:

HEMM belonging to the contractor is deployed in the opencast dump workings.

Potential hazards due to deployment of machinery were assessed on the following

considerations:

Non framing of safe operating procedure or safe maintenance procedure;

Maintenance schedule not followed;

Violation of traffic rules;

Unauthorised operation of machine;

Unskilled operator;

Non provision of safety devices;

By passing safety devices;

Two machines working in close proximity;

Light vehicles moving on haul roads;

Fire in HEMM/ Non-provision of Automatic Fire detection and suppression system

(AFDSS);

Failure of lifting equipment;

Equipment movement procedure near overhead lines.

Observations and comments: During inspection of the mine, the Pay Loader was inspected.

Cabin of the pay loader operator was found to be OK. AVA was also provided. However, rear

view mirrors on both sides were broken. Same should be replaced immediately.

Tipper no. MH40 Y-8683 was inspected and it was found that the canopy is extended. Fire

extinguisher has also been provided. Rear view mirrors are provided. However, propeller

shaft guard and AVA were not provided, same should be provided at the earliest.

Risk arising out of Potential hazards due to deployment of machinery can be addressed

as follows:



Documentation:

Codes of practice for safe operation should be framed separately for each type of

machinery and circulated in Hindi language. Mention may be made in the SOP that ‘on

gradients, turn the dumper steering off centre’.

The code of instructions furnished by the manufacturers in the matter of installation,

operation and maintenance of various machinery/ vehicles and preventive

maintenance schedule for each type of vehicle shall be formulated and strictly

followed.

The codes of practice should be periodically reviewed and modified if needed to ensure

compliance with relevant circulars issued by DGMS from time to time.

Safe operation of machinery:

All the operators shall be duly authorised by the Mine Manager.

To prevent unauthorised driving, a system shall be evolved whereby the ignition key

and/or cabin key shall always remain with the driver/operator or with specifically

designated competent persons.

Only competent/trained operators shall be deployed to operate the machinery. Their

competency should be evaluated by a Board constituted by the company.

The operators may be trained and retrained using simulators.

Periodical tests:

All the machine operators shall undergo regular checks to test their driving/operating skill& knowledge at least once in every 5 years.

Inspection & examinations:

At the commencement of every shift, the operator shall personally examine all

safety devices and shall not take out the machine for work nor shall he work the

machine unless he is satisfied that the vehicle is mechanically sound and in efficient

working order.

He shall report any defect observed, immediately to the manager, engineer or other

competent person.

Only approved type of hydraulic fluids shall be used and same may be tested

periodically for performance i.e. effect on torque, viscosity, water content,

temperature rise etc. and the running hours and consumption pattern shall also be

recorded.

Awareness:

Sign Boards shall be displayed at conspicuous places mentioning safe distance to be

maintained between two machines.

SOPs should be constantly displayed at every relevant place including the haul roads,

rest shelter, canteen etc.

iii) Men and material winding in vertical shaft:

The general requirements of a vertical shaft drum winder are such that it shall be suitable

for the purpose for which it is being used, and shall have effective and suitable:

(a) Brakes;

(b) Brake locking devices and brake interlocking devices;



(c) Means of controlling power to the winding engine;

(d) Means of preventing an over-wind or under-wind;

(e) Means of preventing a conveyance travelling at an excessive speed;

(f) Means of safely stopping and holding a conveyance if an over-wind occurs;

(g) Means of monitoring the movement of every conveyance in the shaft;

(h) Means of detecting slack rope and safely stopping the winder.

The winder is new and all the above requirements are fulfilled at Munsar Mine.

Cages (16 men capacity) are in use for transportation of men. The ROM production of the

mine will be transported to the surface in side tipping tubs of 24 cft (1.6tonnes) capacity.

The risk assessment was carried out on the following considerations:-

Incorrect signaling/non observance of code of signals fixed by the manager;

Fall of the cages due to rope failure;

Uncontrolled movement of cages due to brake failure;

Over-winding when persons are inside the cage;

Cage movement due to failure of sheaves;

Major incident caused by distraction of driver, due to noise from winder, fan or

other noise;

Major incident caused by distraction of driver due to People;

Major incident caused by driver fatigue;

Slipping and falling while entering/leaving the cage;

Struck by burst hydraulic hose;

Caught in moving machinery;

Slipping/falling due to oil/grease on floor;

Electric shock while fault finding on live panels.

iv) Transport of material – Haulage:


Risk assessment from the identified hazards in the operation of haulage transport is based

on the following mechanism:-

A. Struk by Tub or material, due to:

Rope failure;

Failure of Tub coupling;

Drawbar or slings;

Failure of brake;

Unexpected movement of Tubs at incline top or bottom stations;

Unauthorised personnel gaining access to controlled areas.

B. Derailment caused by:

Poor track conditions; Badly loaded material (Timber, Cement, Steel, pipeline etc) from surface; Poor tub condition/non provision of Safety catches; Track switches.

C. Injured while reloading material in incline shaft;



D. Injured while riding on Tubs;

E. Misuse of material movement procedures due to urgency.

v) Explosives and Blasting:


1) Explosives are issued from the Magazine on written requisition from the Blasting

foreman/ mate and countersigned by the Asst. Manager in shift.

2) Blasting is done using 25 mm cartridge slurry explosives in underground at the end of

shift using electric detonators and.

3) Each Blaster is assisted by duly authorised helpers.

4) Blasting card system is not being followed meticulously. The blasters and their helpers

are taking shelter at safe place at the time of blasting of the shots; it may be borne in

mind that negotiating two right angle bends in underground workings would keep the

people out of danger.

5) All the approaches to the place of blasting belowground should be fenced using

portable extendable fencing in scissor shape with radium tape.

6) Underground blasters should be provided with portable red lights in addition to the

individual cap lamps.

7) The key of the exploder is retained by the blaster with him only.

8) It should be ensured that explosives and detonators are carried separately unless they

are to be immediately charged in the shot holes.

9) It should be strictly followed that explosives of only one type are used in one hole.

10) Zone of influence of blasting for underground workings should be determined by the

Manager. Instructions should be issued to the blasters and supervisory staff regarding

examining and securing the roof and sides within the zone of influence before

permitting workers to enter the area of blasting.

11) For safety during drivage from both sides, separate code of practice should be

prepared and copies issued from time to time to concerned persons in the event of

any two working faces approaching within 10 m.

Potential hazards due to explosives and blasting were assessed during Risk Assessment

considering the followings:

Not taking proper shelter;

Possibility of blown through shots;

Not following safe blasting procedures;

Untrained / unauthorized helpers.

vi) Shortage of skilled persons / deployment of unskilled persons:

In mining industry most of the disasters in the past were caused by human errors and

were preventable. Many accidents in the past have been caused either due to shortage of

skilled persons and deployment of unskilled persons.

Unless competent and dependable workmen, operators and officials are available in

mines, no program of promotion of safety can make any real headway.



Risk assessment of human contributory factor in Munsar mine has been carried out on

the following considerations:

Absenteeism;

Training of workmen;

Manpower planning;

Examination for workmanship quality not being done regularly.


The workers engaged in mining industry are generally highly paid. Limited requirements

and lack of knowledge to utilize the money for uplifting their quality of life leads to a

tendency of absenteeism. A well designed human resource development program, proper

assessment and timely availability of manpower will help in curbing the absenteeism. A

well-equipped Group VTC at Munsar Training Centre imparts training to the employees of

Munsar mine. Regular courses should be conducted for the departmental as well as

contractual employees for updating their skills and developing belongingness to the mine.

Risk management due to lack of skilled manpower can be effected as follows:

Contractual employees should be selected on the basis of their educational,

professional and job-need based qualifications, which should be recorded in their

job-Card and employment register (refer DGMS Cir. 01 of 2012).

While doing manpower planning margin must be kept for expected absenteeism.

In addition to the training at the mine, efforts should be put to train the workers by

external competent agencies.

Simulator Training for all the operators should be arranged as recommended vide

DGMS Cir. 4/2011.

Management must take action to recruit required statutory personnel and motivate

the existing employees to take training and clear the examinations being conducted

by DGMS.

A system should be developed for Employees to be examined regarding aptitude and

knowledge required for the job.

Contractor shall be instructed not to employ or terminate his workers without

knowledge of the mine management (refer 11th Safety Conference

Recommendations).

vii) Transportation of ROM from underground stopes:

At Munsar Mine, the ROM transportation is done from underground using 16 cft side

tipping tubs.

Observations and comments: The ore from the face is manually loaded either directly into the ore pass or into the

tubs. The loaded tubs are then unloaded in the ore pass.

From the tramming level, ROM tubs are hauled by battery locomotive upto the incline

bottom on a track laid with 30 lbs rails.



Transport operation should be carried out in such a way that they don’t pose any

hazards to the mine, employees and the equipment. Specially designed Re-railers may be

provided for re-railing the derailed tubs especially on the incline track.

Potential hazards due to rail transportation of ROM were assessed on the following

considerations:

Injury due to lifting of big ore piece or improper way of lifting the boulder;

Injury due to breaking of the boulder midway while carrying;

Extremity caught in between ore piece and the tub body;

Caught in between the tub/Loco and side;

Run over of tub on the foot of the tub pusher;

Jamming of the ore pass due to oversize boulders;

Excess water from the ore pass due to sand stowing in adjoining area;

Ore pass gate operation using improper tools/standing at incorrect position;

Flying fragments hitting the eyes due to simultaneous operation of loading ROM in

the ore pass in the stope and tub loading from the same ore pass at the bottom;

Derailment of tubs/Loco;

Collision of two tubs/Loco;

Poor Loco/tub/track maintenance.

Documentation:

Code of practice for prevention of injuries to persons engaged in ROM transportation

may be formulated and implemented.

Record of examination of loco, tubs with their identification number and history sheet.

Record of tub couplings with date of replacement / year of manufacture.

Inspection and examination:

Before instructing the workers about loading of tubs from the face, tubs, tramline etc

should be inspected by a competent person ensuring the followings:

i) Battery Locomotive, brake, horn, fire extinguisher in particular, safety catches of the

tubs and the track;

ii) Condition of the track, slippers, fish plates, tie rod of the tail piece of the crossings,

presence of water on the track, drainage, etc.;

iii) Condition of the chute gate, dead weight, poking hole, gap between axle and the

chute gate;

iv) Width, inclination and condition of the track upto the point of tipping;

v) Adequacy of lighting at the chutes.

viii) Lack of Safety Awareness:

Everyone who works in the mine, from manager to the youngest worker must be instilled

with the right attitude, consisting of sincere belief that the accidents can be prevented with

safety awareness in mind, and a commitment to put into practice everything which can

contribute to accident prevention.



Risk assessment to identify the hazards due to lack of safety awareness amongst the

employees at Munsar Mine was studied on the following lines:

Non-existence of documented procedures

Improper/ inadequate training

Improper communication

Inadequate publicity / Objective not explained.


At Munsar Mine, contractor’s employees are also deployed. Safety awareness assumes

importance in light of the fact that there is a new batch of workers every now and then.

System for reminding the use of PPE through public address system at the beginning of

the shift may be introduced. Safety week and safety fortnight be celebrated encouraging

inter- sectional safety inspections and winners of different competitions held during such

celebration should be suitably awarded.

A scheme may be incorporated wherein safe worker of the month and Gem of the month will be chosen from amongst the safe employees. His photo may be displayed on the specified notice board. Further, safety suggestion of the month can also be invited; ensuring participation of larger group including contractual employees and the best suggestion may be suitably rewarded.

“Safety is my responsibility” Card in Hindi language containing 10 very important

questions has been issued to all the workers with instructions that no work should be

started by any worker without asking these 10 questions. Whenever answer to any one of

the questions is ‘No’, the worker should be urged to take the matter to his supervisor for

initiating corrective measures. (Refer Cir. 04 of 2013).

ix) Environmental issues:

Underground Mining at Munsar Mine and ore handling/processing is likely to generate Air Pollution, Water Pollution and Noise Pollution which is likely to cause adverse impact on the surrounding environment, flora and fauna.

During Identification of potential hazards and assessment of the risk arising out of

those hazards following issues were considered:

Airborne dust generated by machines, by Blasting operation & ore transport system;

Inadequate lighting in mine;

Excessive noise level;

Inadequate Tree plantation;

Effect of mining on water table;

Adverse effect on flora, fauna, aquatic lives and habitat.

Observations and comments: Four ambient air monitoring stations have been established at the mine for PM10,

PM2.5, SO2, NOx& CO monitoring. Location of the stations has been decided based on

the meteorological data, topographical features and environmental conditions.

Ambient air quality monitoring is being carried out quarterly.



Ambient noise monitoring stations (4 nos.) have been established.

No mine water is allowed for outside discharge; all the mine water produced is treated

in settling pond and re-used for:

Sand Stowing;

Surface& underground drilling;

Dust suppression.

Storm water and runoffs from old waste dump area is routed through network of

catch/garland drains.

Following actions are required to control the environmental risk:

During monsoon additional precautions should be taken to clean the garland drains.

Fugitive dust emission from all the sources should be regularly monitored &controlled

by water sprinkling on mine roads, loading & unloading points and at transfer points.

Workers exposed to high dust level should mandatorily use dust masks.

Illumination Survey should be done at regular interval and needful should be done to

rectify the defects if any.

Measurement of noise level should be periodically conducted, so as to control the

noise level below 85dBA in the work environment and wherever the noise level

exceeds the permissible level ear muffs should be made mandatory.

Regular monitoring of water samples should be continued. Water potability test

should be regularly conducted.

x) Occupational health:

During the Risk assessment, records maintained at the mine were studied to assess the

potential hazard to the health of employees.


Periodic Medical Examination (PME) of 20% departmental workers is carried out

annually.

PME covers pulmonary function, vision, hearing, ECG & cardiac function, blood tests,

ultra-Sonography of abdomen, liver function, renal function, HIV, PSA, and STD.

A Hospital is established at Munsar Mine.

Workers’ medical records should be maintained up to 5 years after retirement of the

worker.

Risk management for occupational health hazards involves regular health check of all

the employees. IME/PME as per the recommendations of 10th safety conference should

be done and computerized record should be maintained.

The PME of group of workers deployed in areas prone to generate dust should be

conducted at an interval of 6 months (refer DGMS Cir.1/2011).

Initial and periodic medical examinations including occupational safety and health

surveillance of all contractual employees shall be conducted by an expert agency once

in at least three years or at lesser interval (refer DGMS Cir. 01/2012).

The Mine dispensary may be developed as an occupational health centre fulfilling all

the requirements of the 7th Safety Conference.



xi) Improper Surveying:

Survey and levelling for preparation of statutory plans and sections and updating the

position of the workings are very important. Similarly linking of mine plans to national grid is

mandatory.

While evaluating the risk due to improper survey work, the following aspects were

looked into:

Calibration of instruments not being done regularly;

Surveying not done in time;

Incompetent surveyors;

Shortage of surveyors;

Not correlating mine plans and not linking them to the National grid accurately.

Observations and comments: Survey work is carried out using ‘Total station’ and sophisticated computer software in

AutoCAD.

Competent and qualified surveyor has been appointed at the mine to carry out

surveying jobs.

xii) Inadequate training facilities:

Group VTC has been established at the mine premises. It is equipped with various

training aids and qualified personnel have been appointed for training the employees.

The risk assessment has been made keeping in view the followings :-

Non-existence of training schedule for skill development;

Untrained trainers;

Infrastructure not as per requirement;

Non-existence of feedback /test system.

Observations and comments: Simulator Training for all the HEMM operators (Departmental as well as

contractual)as recommended vide DGMS Cir. 4/2011 may be arranged.

The training centre at Munsar is equipped with the modern training aids such as LCD

projector. DVDs on various topics may be procured/ prepared for further

improvement in training.

Special emphasis should be given to the training of contractual manpower especially

in operation of HEMM, roof and side dressing and roof bolting operation.

A Board should be constituted to evaluate the competence of trainees especially

HEMM operators. Regular checks should be conducted to test their driving/operating

skill, knowledge at least once in every 5 years.

xiii) Fires:

Fires are best controlled at initial stages. Portable fire extinguisher of adequate size

should be kept at all places in mines where a fire is likely to occur. Sufficient number of

persons, especially machine operators and helpers should be trained in the use of these fire

extinguishers. Such persons should be familiar with the position of all the fire-fighting

equipment provided in general and near their places of work in particular. Mock rehearsal at

regular interval should be conducted.



Code of practice for dealing with fires at different locations, machineries, vehicles etc.

should be formulated and a proper firefighting organisation should be formed at the mine.

Automatic fire detection and suppression system (AFDSS) may be fitted on all the

HEMM as recommended vide DGMS Cir. No10 of 2004.

Risk assessment from fire was conducted assuming the following situations:

Fires in diesel operated machinery;

Electrical fires;

Fire during gas cutting;

Spilled off lubricants.


All high pressure hydraulic hose must confirm to the specification as laid down by the

OEM and their quality to be ensured. The hoses shall be replaced at the prescribed

interval or earlier if there is any sign of deterioration.

Up-to-date list of locations/places should be maintained at the mine including vehicles

where fire extinguishers have been provided.

xiv) Poor Supervision: Supervision of work in mines has direct bearing on safety of workers and hence it must

be ensured that a clear policy of regular recruitment of statutory manpower be framed and

implemented by the mine management.

While assessing risks arising out of inadequacy of supervision following aspects were

considered:-

Negligence/ lack of commitment;

Not having proper knowledge / experience;

Inadequate training;

Shortage of supervisors.

Observation and comments: Required number of competent supervisors has been appointed at the mine. Following

action is needed to manage the risk arising out of poor supervision:

Advance manpower planning should be done keeping in view the future requirement of supervisors possessing requisite competency certificates.

Safety culture needs to be improved to ensure the compliance of statutory

provisions and proper discipline especially amongst the contractual employees.

In addition to the statutory training and in-company training, supervisors should also

be exposed to out-company training programs.

Trainers may be trained by outside agencies to ensure quality of training.

xv) Inundation:

At Munsar mine danger due to inundation is apprehended only in the event of failure of

underground pumps.

Risk assessment from inundation angle was conducted assuming the following

situations:

Non formation/ non availability of proper garland drains around the mine entry;



Clogging of garland drains ;

Inadequate pumping capacity;

Poor maintenance of pumps;

Sudden inrush of water through the vertical shaft due to cloud bursts, heavy rains

and failure of surface drainage system.

Observations and comments: Adequate capacity pumps have been installed in all the underground sumps and

additional pumps are also kept as standby.

Risk management for inundation needs the following actions:

Formation/ cleaning of drains should be ensured before every monsoon to ensure

unobstructed flow of rain water.

Pumps should be maintained in good working order especially during monsoon.

Present sump and pumping capacity are adequate to deal with the underground

water which should be regularly monitored/reviewed.

xvi) Unauthorized entry near hazardous operations:

Risk assessment in the event of following possibilities was quantified:-

Trespassing by villagers;

Intention of theft;

Employment of adolescents;

Unauthorized deployment;

Family members entering in the mine along with workers on duty.

Observations and comments: Round-the-clock security is exercised by departmental security guards comprising of

mostly ex-servicemen at all the check posts. Sign boards prohibiting unauthorized entry

have also been displayed at prominent places.

xvii) Manual sizing, sorting and stacking of ore:

At Munsar mine, there is no crushing & screening plant. As such, the breaking, sizing, sorting

& stacking of ROM are done manually by contractual labourers.

The risk associated with this manual work has been assessed as given below:

Strains and sprains from lifting loads improperly or from carrying loads that are

either too large or too heavy;

Hit due to flying pieces;

Extremity being caught in between objects;

Fall of material not stacked properly including rolling stones;

Fall of person on level ground or from wooden platform while loading the truck;

Adverse effect on health due to airborne dust.

xviii) Manual loading of ore into trucks:

Sized ore is manually loaded into trucks for dispatch. The risk associated with this manual

work has been assessed as given below:

Strains and sprains from lifting loads improperly or from carrying too heavy loads;



Hit by falling/rolling ore pieces during loading in basket from heap/stack/truck,

carrying and loading into the truck;

Run Over by Truck/ Jeep;

Fall of person from Ramp/Platform during loading into truck.

xix) Electrical Shock or short circuit in the use of electrical equipment/machinery:

The risk assessment in connection with electrical shock or short-circuit are given below:

Bypassing electrical protective devices;

Unskilled electricians/helpers;

Inadequate support of power cable;

Temporary joints in lighting cable.

As per the guidelines vide DGMS Cir 13 of 2002 entire risk assessment exercise has

been tabulated as follows:-

Table -1 Scales of Consequence, Probability & Exposure

Consequence Scale Probability Scale Exposure Scale

Several dead 5 May well be

expected

10 Continuous 10

One dead 1 Quite possible 7 Frequent (daily) 5

Significant chance of

fatality

0.3 Unusual but possible 3 Seldom (weekly) 3

One permanent disability

/less Chance of fatality

0.1 Only remotely

possible

2 Unusual

(monthly)

2.5

Many lost time injuries 0.01 Conceivable but

unlikely

1 Occasional

(yearly)

2

One lost time injury

0.001 Practically

impossible

0.5 Once in 5 years 1.5

Small injury 0.0001 Virtually impossible 0.1 Once in 10 years 0.5

Once in 100

years

0.02

RISK SCORE= CONSEQUENCE x LIKELIHOOD (PROBABILITY x EXPOSURE)

The above values have been used to calculate the risk score of various hazards



Table - 2

Step: 2 Identifying mechanisms contributing principal hazards and ranking – Munsar Mine

Sr. No.

Major hazard Mechanism Conse. Proba. Expo. Risk score

Remarks

1 Improper Strata control

Failure to identify bad roof

5 3 5 75 RMR of the associated rock varies from 55-66 i.e. Fair roof, hence probability of failure to identify bad roof is considered as unusual but possible. Improper loose

dressing 5 3 5 75

Improper supervision 5 3 5 75

Competent supervisors have been appointed hence probability is considered as unusual but possible.

Lack of proper organisation for erecting supports

5 2 5 50 Experienced support team is engaged hence probability is considered as only remotely possible.

Poor workmanship 5 3 5 75

Anchorage testing is done to ascertain the quality of bolting however, supporting is a regular process; hence probability of poor workmanship is considered as unusual but possible.

Inadequate support design

5 7 5 175

Conventional Support system is designed based on previous study but no fresh scientific study has been carried out. SSR has been framed and followed. Hence probability is considered as quite possible.

Poor quality of support material

5 3 5 75

Only approved type material is procured and used however, the testing procedure for roof bolting is not as per the requirement (refer DGMS Cir. 11/ 2009 and 03/2010);hence, probability is considered as unusual but possible.

Broken scaling bars, tools

0.3 3 5 4.5 Crowbars and Ballam are provided for scaling of the roof; hence, probability is considered as unusual but possible.

Lack of proper system of reporting between statutory supervisors during shift changeover

5 3 5 75

Instruction register is maintained in each shift and the shift supervisors are writing instructions related to supporting of the workings for successors; hence probability is considered as unusual but possible.

Loose dressing at faces 5 3 3 45 Care is taken while dressing high faces; however,



Sr. No.


Remarks

where height is more than 3 m

probability is considered as unusual but possible.

2 Poor Supervision Negligence/ lack of commitment

5 3 5 75 Supervision is exercised by the competent supervisors hence probability is considered as unusual but possible.

Not having proper knowledge / experience

5 3 5 75 A combination of new and experienced supervisors has been appointed; hence probability is considered as unusual but possible.

Inadequate training 0.3 7 5 10.5

Non-availability of facilities for structured training of frontline supervisors; hence probability is considered as quite possible.

Shortage of supervisors 0.3 3 5 4.5

Required number of supervisors has been appointed hence probability is considered as unusual but possible.

3 Inundation Non availability of proper garland drains 0.3 3 2 1.8

Garland drains provided. Regular cleaning of garland drains is done; hence probability is considered as unusual but possible.

Non formation of drains around the mine entry

0.3 3 2 1.8 Drainage has been provided near mine entry hence probability is considered as unusual but possible.

Clogging of garland drains /Failure of surface garlands

0.3 3 2 1.8 Surface garland drains are cleaned regularly especially before monsoon. UG drains are cleaned at regular interval; hence probability is considered as unusual but possible.

Inadequate pumping capacity

0.3 3 5 4.5

Pumps of adequate capacity have been installed belowground and sumps are regularly cleaned as per planning /schedules; hence probability is considered as unusual but possible.

Poor maintenance of pumps 0.3 3 5 4.5

Pumps are being regularly maintained in good working order; hence probability is considered as unusual but possible.

Encountering sudden inrush of water from the drill holes made for roof support

0.3 2 2 1.2

Cavity zones are rarely observed; hence probability is considered as only remotely possible.



Sr. No.


Remarks

Inrush of water from punctured boreholes into current excavations

1 1 2.5 2.5

Remote chance of intercepting boreholes during development drivage; hence probability is considered as conceivable but unlikely.

Inrush of water due to cloud bursts, heavy rains through surface bore holes

1 1 2 2

All the surface boreholes have been sealed/ plugged; hence probability is considered as conceivable but unlikely.

4 Training facilities inadequate

Nonexistence of training schedule for skill development

0.3 3 5 4.5 Training schedule exists; hence probability is considered as unusual but possible.

Untrained trainers 0.3 7 5 10.5

Trainers are not being trained in the use of latest training aids including simulators hence probability is considered as quite possible.

Infrastructure not as per requirement

0.3 3 5 4.5 Group Vocational Training centre is established at Munsar. Hence probability is considered as unusual but possible.

Non-existence of feedback /test system 0.3 7 5 10.5

System of feedback/test of all the trainees at the end of training is not in existence; hence probability is considered as quite possible.

5 Shortage of skilled persons / deployment of unskilled persons

Absenteeism 0.3 7 5 10.5

Incidence of absenteeism amongst the piece rated workers is high hence probability is considered as quite possible.

Training not done as per requirement

0.3 3 5 4.5 Training is done as per statutory requirement; hence probability is considered as unusual but possible.

Manpower engagement not as per requirement

0.3 3 5 4.5 In addition to the departmental manpower, contractual manpower is engaged as per requirement hence probability is considered as unusual but possible.

Examination for workmanship not done regularly

0.3 7 5 10.5 There is no system of examination of workmanship; hence probability is considered as quite possible.

6 Lack of safety awareness


0.3 3 5 4.5 Codes of practice have been framed in English as well as Hindi for all the operations hence probability is considered as unusual but possible.



Sr. No.


Remarks

Improper/ inadequate training 0.3 3 5 4.5

Training methodology needs to be updated by use of simulators for training of HEMM operators; hence probability is considered as unusual but possible.

Improper communication 0.3 3 5 4.5

Telephones have been provided belowground; hence probability of improper communication is considered as unusual but possible.

Inadequate publicity / Objective not explained

0.3 3 5 4.5 Instructions are given by the supervisors at the beginning of shift reminding employees of safety practices; hence probability is considered as unusual but possible.

7 Improper surveying

Calibration of instruments not being done regularly

0.3 2 10 6 Calibration is done annually; hence probability is considered as only remotely possible.

Surveying not done in time

0.3 3 10 9 Surveying is done as per requirement of statute; hence probability is considered as unusual but possible.

8 Explosives and Blasting

Not taking proper shelter

5

3

5

75

Blasting card system is not meticulously followed; hence probability is considered as unusual but possible.

Possibility of blown through shots

5 3 5 75 Care is taken to stop the face from one side; hence probability is considered as unusual but possible.

Not following safe blasting procedure

5 3 5 75 Safe blasting procedures are followed; hence probability is considered as unusual but possible.

Untrained / unauthorized helpers

5 3 5 75 Only authorized helpers are engaged in explosive handling; hence probability is considered as unusual but possible.

9 Use of Machinery Non-framing of SOP/COP for erection, installation, operation, maintenance, repair etc. of each equipment/each operation.

5 3 5 75

SOP for operation and maintenance of HEMM has been framed. Hence, probability of non-framing of SOP is considered as unusual but possible.

Slip/trip while entering or leaving equipment

0.01 3 5 0.15 Operators/mechanics are competent and trained. They are vigilant while entering or leaving the equipment; however



Sr. No.


Remarks

given the frequency with which access and egress from equipment occurs, probability is considered as quite possible.

Maintenance schedule not followed 5 7 5 175

Contractual HEMM is deployed and the same is repaired/maintained outside the mine lease hence probability is considered as quite possible.

Overheating of the engine and spillage of oil/inflammable liquid.

5 3 5 75 Machines are inspected daily; hence probability is considered as unusual but possible.

Violation of SOP/COP 5 7 5 175

Contractual operators are engaged in the mining activities; hence violation of SOP/COP is considered as quite possible.

Unauthorized operation of machinery 5 7 5 175

Contractual HEMM operation is being carried out; hence probability is considered as quite possible.

Unskilled operators 5 7 5 175

Bypassing safety devices 5 7 5 175

At the time of inspection AVA of a tipper (MH 40 Y8683 was not in working order, hence probability of bypassing safety devices is considered as quite possible.

Extremity caught in between while transporting hand held machinery

.01 7 5 0.35

Hand held jack hammer machines are extensively used in the mine for drilling; hence probability during transportation of machine is considered as quite possible.

Hit by compressed air hose pipe due to bursting or decoupling from the hose nut/clamp.

.01 7 5 0.35

Compressed air is extensively used for drilling and auxiliary ventilation; hence probability is considered as quite possible.

Hit due to uncontrolled movement of air leg

.01 7 5 0.35 Air legs are extensively used in the mine; hence probability is considered as quite possible.

10 Men and material winding in the

Improper maintenance of the winding

5 3 10 150 Maintenance is being done under the supervision of engineer but it is a regular and important activity. Hence



Sr. No.


Remarks

newly commissioned vertical shaft

accessories probability of faulty maintenance is considered as unusual but possible.

Incorrect signaling/non observance of code of signals fixed by the manager

5 1 10 50

Signals received from the underground banksmen are confirmed by the banksman at the pit top who is also provided with Telephone; hence probability is considered as conceivable but unlikely.

Fall of the cages due to rope failure

5 3 10 150

Daily, weekly and monthly rope examination is done by competent persons and electromagnetic rope test is also carried out at six-monthly intervals; hence probability is considered as unusual but possible.

Uncontrolled movement of cages due to brake failure

5 3 10 150 Two braking systems provided and examination & testing of the brakes is done regularly by competent persons; hence probability is considered as unusual but possible.

Over-winding when persons are inside the cage

5 3 10 150 Automatic contrivances are provided and are regularly checked for effectiveness; hence probability is considered as unusual but possible.

Fall of cages due to failure of rope attachments in headgear

5 3 10 150

Approved type rope attachments are procured & used. Regular inspection is carried out by competent persons; hence probability is considered as unusual but possible.

Cage movement due to failure of sheaves

5 3 10 150

Approved type of sheave is used and regular inspection is done by competent persons; cleaning & greasing are carried out regularly hence probability is considered as unusual but possible.

Slipping and falling while entering/leaving the cage

1 3 10 30 The cages have been provided with gates but the same have not been interlocked with the winder brake; hence probability is considered as unusual but possible.

Unauthorized/unskilled driver 5 3 2 30

Adequate number of competent WE drivers have been appointed hence such probability is considered as unusual but possible.

Major incident caused by distraction of driver,

5 1 10 50 The driver is provided with enclosed cabin and only authorized persons are allowed to enter the winding engine



Sr. No.


Remarks

due to noise from winder, fan or other noise.

room hence probability is considered as conceivable but unlikely.

Major incident caused by distraction of driver due to People

5 1 10 50

Major incident caused by driver fatigue

5 3 10 150

Sufficient winding engine drivers have been appointed and generally no operator is required to perform over time duty; hence probability is considered as unusual but possible.

Caught in moving machinery 0.3 2 10 6

Guards have been provided on immediately accessible parts and authorized access in the W. E. Room; hence probability is considered as only remotely possible.

Struck by burst hydraulic hose

0.3 2 10 6

Quality hoses are purchased from authorized suppliers and during daily and weekly inspection the fitters are checking the hoses and restricted entry in the machine area hence probability is considered as only remotely possible.

Slipping/falling due to oil/grease on floor 0.3 2 10 6

Spills are cleaned up regularly and non-slip floor provided at the W.E. Room; hence probability is considered as only remotely possible.

Electric shock while fault finding on live panels

1 3 5 15

Suitable test equipment have been provided, trained competent persons are deployed and circuit diagrams are available; hence probability is considered as unusual but possible.

11 Transportation of material - Haulage

Struck by Tub or material, due to: Rope failure

0.3 3 5 4.5

Regular inspection and regular re-capping is being done. Interconnected run away switch and stop block, Drag/backstay are also attached to the ascending tub; hence probability is considered as unusual but possible.

Failure of Tub coupling, drawbar or slings 0.3 3 5 4.5

Regular inspection and timely replacement of the coupling is done; hence probability is considered as unusual but possible.



Sr. No.


Remarks

Failure of brake 0.3 3 5 4.5

Brakes are regularly tested and no incidence of brake failure in the past; hence probability is considered as unusual but possible.

Unexpected movement of Tubs at pit top or bottom stations

0.3 3 5 4.5

Proper signaling arrangement is provided and the haulage is operated only after getting clear signals; hence probability is considered as unusual but possible.

Unauthorised personnelgaining access to controlled areas

0.3 3 5 4.5

Only authorized persons are allowed near the haulage room or near the track; hence probability is considered as unusual but possible.

Derailment caused by: poor track conditions 0.3 7 5 10.5

Tracks are maintained in good order, however there are incidence of derailment; hence probability is considered as quite possible.

Derailment caused by: obstructions (badly loaded scrap and material)

0.3 3 5 4.5

Adequate precautions are taken while transporting scrap or material to surface; hence probability is considered as unusual but possible.

Badly loaded material (Timber, Cement, Steel, pipeline etc.). from surface

0.3 3 5 4.5

There is separate trolley for transportation of timber/pipelines etc. hence probability is considered as unusual but possible.

Derailment caused by poor tub condition/non provision of Safety catch

0.3 7 5 10.5

Tubs have been properly numbered and are being maintained regularly but safety catches were not found in some of the tubs; hence probability is considered as quite possible.

Derailment caused by track switches

0.3 3 5 4.5 All the switches are also maintained periodically; hence probability is considered as unusual but possible.

Injured while reloading material on inclines

0.3 3 3 2.7 Re-loading material on the inclines is done under the personal supervision of the mining mate; hence probability is considered as unusual but possible.

Injured while riding on 0.3 3 5 4.5 No person is allowed to travel on tubs and this is ensured



Sr. No.


Remarks

Tubs by strict supervision; hence probability is considered as unusual but possible.

Misuse of material movement procedures due to urgency

0.3 7 3 6.3

Generally the material movement procedure is followed; however under production pressure such probability is considered as quite possible.

12 Fires Fires in Diesel operated machinery

0.3 7 5 10.5 Spillage of oil on heated engine parts is quite possible.

Electrical fires 0.3 7 5 10.5 Short circuit in electrical circuit is quite possible.

Fire during gas cutting 0.3 7 3 6.3 Leaking gas pipeline/backlash causing fire is quite possible.

Spilled off lubricants 0.3 7 2 4.2 Spillage while filling the lubricant is quite possible.

13 Transportation of ROM from the ore pass to the pit bottom

Hit by ore pieces while clearing ore pass clogged due to oversize boulders

0.01 7 5 0.35

The ore is hard hence probability is considered as quite possible.

Slip/trip due to excess water from the ore pass due to sand stowing in adjoining area

0.01 7 3 0.21

Clogging of drains is quite possible which may result in slip/trip of persons hence probability is considered as quite possible.

Hit by ore piece during ore pass gate operation using improper tools/standing at incorrect position

0.01 7 5 0.35

During loading ore into the tubs injury may occur due to negligence; hence probability is considered as quite possible.

Hit by derailed tubs

0.3 7 5 10.5 Incidence of tub derailment is not uncommon; hence probability is considered as quite possible.

Hit due to extremity caught in between two tubs

0.3 3 5 4.5

Tubs are hauled by battery loco hence, probability is considered as unusual but possible.



Sr. No.


Remarks

Rolling stones while transportation or tipping of tubs in ore cleaning floor

0.01 7 5 0.35

Overloading of tubs is controlled by the supervisors however, while tipping at surface probability of rolling stones is considered as quite possible.

Poor loco/tub/track maintenance

0.01 3 5 0.15 Loco/Tub and track maintenance is being done regularly; hence probability is considered as unusual but possible.

14 Environmental issues

Lack of backfilling of solid wastes and non-stabilisation of existing OB dumps.

0.3 7 5 10.5

OB/ wastes from dump mining are being disposed in external waste dumps. No backfilling is being done in abandoned opencast pits filled with water. Due to dump mining sub-grade dump stability has been disturbed. Study of slope stability of dumps is not done. Hence the probability is considered as quite possible.

Inadequate capacity of Catch drain, garland drain and siltation ponds & lack of de-silting.

0.3 3 5 4.5

Catch/garland drains have been constructed around mine pits and dumps to channelize surface run-off during monsoon. But no siltation pond has been constructed. Desilting of drains is done periodically but drain cross-section is inadequate at places. Hence the probability is considered as unusual but possible.

Dust pollution due to lack of control on fugitive emission and dust. 0.3 7 5 10.5

Fugitive dust emission occurs in UG drilling & mucking and on roads & siding on surface. Wet drilling is being practiced in underground. On surface, only 1 no. Mobile tanker of 5 KL capacity is inadequate for dust suppression. Plantation has been done for absorption of dust. Permanent fixed water sprinklers not installed. Roads are not made bitumen top. Hence probability is considered quite possible.

Lack of control on noise pollution and workers not wearing ear plugs/muffs. 0.3 7 5 10.5

Excessively high noise >100 dB(A) is generated from jack hammer drill at underground as per quarterly noise monitoring report. Noise monitoring is done quarterly instead of fortnightly as per statute. Workers have been provided with ear plugs/muffs as informed but no one was found using the same while working at/near drill or ventilation fan. Hence probability is considered as quite



Sr. No.


Remarks

possible.

Workers vulnerable to contracting dust related diseases.

0.3 3 10 9

High dust areas have not been identified & PME is not being conducted as per directive. PME of workers engaged in areas prone to generate air borne dust are not done at every 6 months as prescribed. There has been no incidence of notified dust related disease, as informed. Hence probability is considered as unusual but possible.

Improper disposal of Hazardous wastes at workshop.

0.3 2 5 3

Only Used oil is generated in small quantity as hazardous wastes which is stored in barrels & disposed to registered recyclers or re-used in mine.. Oil filters, oil hoses and cotton wastes are not generated in this UG mine. The probability of unsafe condition due to hazardous wastes is considered as remotely possible.

15 Occupational health

Occupational health hazard- Unfit for duty

0.3 2 5 3

There is no incidence of any notified disease till date and medical examination of all the employees is conducted as per the statute; hence probability is considered as only remotely possible.

16

Electrical Shock or short circuit in the use of electrical equipment/machinery

Bypassing electrical protective devices

0.3 3 5 4.5 Bypassing earth leakage relay or overload relay in gate end boxes and switches is unusual but possible.

Unskilled electricians/helpers

0.3 3 5 4.5 Competent electricians have been appointed hence probability is considered as unusual but possible.

Inadequate support of power cable.

0.3 3 5 4.5 Power cables are properly supported on hooks; hence probability is considered as unusual but possible.

Temporary joints in lighting cable

.0001 7 5 .0035 Temporary joints were observed in lighting cables; hence probability is considered as quite possible.

17 Unauthorized entry near hazardous operations

Trespassing by villagers to avoid long route 0.3 7 5 10.5

Village Waitola is nearby and the area has been partly fenced. Hence, probability is considered as quite possible.

Intention of theft 1 7 10 70 Due to the proximity of village such probability is considered as quite possible. Curious onlookers

around Machine 0.3 7 5 10.5

Employment of 0.3 2 5 3.0 No person whether departmental or contractual is



Sr. No.


Remarks

adolescents appointed without initial medical examination (IME); hence such probability is considered as only remotely possible.

Unauthorized deployment

0.3 7 5 10.5 All the contractor’s workers have not been issued photo identity cards; hence such probability is considered as quite possible. Family members

entering in the mine along with workers on duty.

0.3 7 5 10.5

18 Manual sizing, sorting and stacking of ore

Strains and sprains from lifting loads improperly or from carrying loads that are either too large or too heavy

0.1 7 5 3.5

Ore is manually loaded into basket hence probability is considered as quite possible.

Hit due to flying pieces 0.1 7 5 3.5

Breaking and sizing of ore is done using hammers hence probability of being struck by flying pieces into eyes or other parts of body is considered as quite possible.

Extremity being caught in between objects

0.1 7 5 3.5 Sizing of ore is done by small hammers hence probability of fingers of the palm getting caught in between the hammer and the ore piece is considered as quite possible.

Fall of material not stacked properly including rolling stones

0.1 7 5 3.5 Ore is stacked manually, hence, such probability is considered as quite possible.

Fall of person on level ground or from wooden platform while loading the truck

0.1 7 5 3.5

Ore is loaded into trucks manually, hence, such probability is considered as quite possible.

Adverse effect on Health due to airborne dust

0.3 3 5 4.5 Till date no incidence of adverse effect on health of any worker due to dust has been reported; hence probability is considered as unusual but possible.

19 Manual loading of ore into trucks

Strains and sprains from lifting loads

0.1 7 5 3.5 Ore is loaded into trucks manually with the use of spade and basket; hence probability is considered as quite possible.



Sr. No.


Remarks

improperly or from carrying too heavy loads Hit by falling/rolling ore pieces during loading in basket from heap/stack/truck, carrying and loading into the truck

0.1 7 5 3.5

Manual loading is done without use of hand/forearm gloves; hence probability is considered as quite possible.

Fall of person from Ramp/Platform during loading into truck

0.1 7 5 3.5 Truck loading is done using ramp/platforms; hence probability is considered as quite possible.

Run Over by Truck/ Jeep 0.3 3 5 4.5

The ore is transported from the mine in trucks under the supervision of competent supervisors. Hence, probability is considered as unusual but possible.



Table –3 Step2: Initial Hazard identification, Risk Assessment and Ranking:

Sr.

No. Description of Hazard

Conse. Proba. Expo. Risk

score

Risk

Ranking

1. Improper Strata Control 5 7 5 175 I

2. Use of Machinery 5 7 5 175 I

3. Men and material winding in vertical shaft

5 3 10 150 II

4. Explosive and Blasting 5 3 5 75 III

5. Poor Supervision 5 3 5 75 III

6. Unauthorized entry near hazardous operations

1 7 10 70 IV

7. Environmental issues 0.3 7 5 10.5 V

8. Transportation of material - Haulage 0.3 7 5 10.5 V

9. Shortage of skilled persons/ deployment of unskilled persons

0.3 7 5 10.5 V

10. Fires 0.3 7 5 10.5 V

11. Training facilities inadequate 0.3 7 5 10.5 V

12. Transportation of ROM from the ore pass to the pit bottom

0.3 7 5 10.5 V

13. Improper surveying 0.3 3 10 9 VI

14. Manual sizing, sorting & stocking of ore

0.3 3 5 4.5 VII

15. Manual loading of ore into trucks 0.3 3 5 4.5 VII

16. Lack of safety awareness 0.3 3 5 4.5 VII

17. Inundation 0.3 3 5 4.5 VII

18. Electrical Shock or short circuit in the use of electrical equipment/machinery

0.3 3 5 4.5 VII

19. Occupational health 0.3 2 5 3 VIII



Risk Calculation based on DGMS (Tech) Circular (MAMID)/01/2014;



The following risk assessment matrix has been used to categorize risks:



On the basis of above, the identified hazards for Munsar Mine are tabulated below:

Step 3 Catastrophic Major Moderate Minor Negligible

Almost Certain

None None None None None

Likely None None None None None

Possible

None

Use of Machiner

y Extreme

Explosive and blasting

High Environmental issues

Medium

Manual loading into

trucks Low

Improper strata

control Extreme

Poor supervision

High Transportation of material - Haulage

Medium

Electric Shock Low

Occupational health

Low Men &

Materials winding

in vertical

shaft Extreme

Unauthorised Entry near hazardous

operations High

Shortage of skilled personnel Medium

Inundation Low

Manual

Breaking & Sizing of ore

Low Transport of ROM

from ore pass

Medium Lack of safety

awareness Low

Unlikely None None

Fires Medium

Improper Survey Low

None Rare None None

Training facilities inadequate

Medium None

Personal risk assessment based on DGMS (Tech) Circular (MAMID)/02/2014;

Take 5 (Personal Risk Assessment Process) shall consist of the following steps:

1. Stop, step back, observe: Observe the work area and surrounding location for hazards; 2. Think through the task: Consider the sequence of steps involved in carrying out the task from

start to finish; 3. Identify any hazards: Identify the hazards associated with the task including any hazard present in

the immediate and surrounding work area as well as hazards generated by the task. 4. Control the hazards: If the hazard is not controlled and the work area not safe – do not start

work, report to your superior official to review the risk assessment. 5. Complete the task: Once all control measures have been safely implemented – commence the

task.



Sample card recommended vide the above mentioned DGMS (Tech) Circular

(MAMID)/02/2014 is given herewith for ready reference:

Take 5(Personal Risk Assessment)

1) STOP! THINK THROUGH THE TASK

Get the correct

Think About

Information Procedures/SWMS Tools & equipment

The people /systems affected

Safe access/exits Permits

Nearby equipment Task setup Environment impact

Alternative methods

2) LOOK FOR HAZARDS

Look close look after look above look below

What hazards are there?

Atmospheric Environmental Manual handling Radiation

Biological External Mechanical Thermal

Chemical Fire/Explosions Pressure

Electrical Gravitational Psychosocial

What if it?

Breaks Falls Leaks Spills

Doesn’t fit Ignites Shrifts

Explodes Jams Slips

What if it is?

Too heavy Labelled incorrectly Sharp

Energized Poisonous The wrong one

Hot Pressurized Too big/small

What if I’m?

Caught in In need of assistance Too slow

Confused Struck Uninformed

What if I?

Inhale Make an error Slip/trip

Let go Need help

3) MAKE THE HAZARDS SAFE

What is the probability of the event occurring?

What are the consequences of the event occurring?

Calculate the risk 4) MAKE THE HAZARDS SAFE

1) Eliminate. Completely remove the hazard from the workplace. 2) Substitute. Substitute the hazard with something of a lesser risk. 3) Isolate. Isolate the hazard from anyone who could be harmed. 4) Engineer. Re-design the process or equipment to control the hazard. 5) Administer. Control the hazard by influencing others on how to reduce the risk. 6) Personal protective equipments (PPE). Use appropriate PPE to protect against the hazard.

5) COMPLETE THE TASK SAFELY All work activities should be given a final check to identify and control any potential hazards that may have not already been addressed prior to commencement of activities. All frontline supervisors may be advised to use the card given below, from the very beginning to the end of any task just by making a tick mark in the ‘Yes’ or ‘No’ column from top.



TAKE 5 (Personal Risk Assessment)

Task……………………………………………………………………………………………………………………………………………….. Location……………………………………………………………………………………………………………Date…………………….. 1. STOP! THINK THROUGH THE TASK Yes No Am I clear on what the task is?

Do I have the required skills, training and licenses for the task?

Is there a Safe Operating Procedure available?

Is a work permit and/or an authority to work required?

Is my equipment correct for the task and in good working order?

Do I have the correct personal protective equipment?

2.LOOK FOR HAZARD

1. Atmospheric Weather extreme, high, humidity, dust, dangerous gases, lack of oxygen…….

2. Chemical Acids, bases, solvents, heavy metals, poisons, particulates, fumes, vapours…

3. Environmental Confined spaces, poor lighting, loud noise, temperature, poor ventilation……

4. External Traffic other workers, general public.

5. Fire/Explosions Open flames combustible materials, electrical arching, chemical reactions…..

6. Gravitational falls, slips, trips, falling objects.

7. Manual handling Lifting, pulling, pushing, twisting, awkward positions, changes in levels…

8. Mechanical Impact, entanglement, stabbing, crushing, suction, abrasions protrusions…..

9. Pressure Air, Water, Oil, gas, vacuums, high/low pressures

10. Radiation UV, Infra-red, lasers, X-rays, sunlight…..

11. Thermal Hot or cold surfaces, hot or cold liquids, steam, friction…..

3.ASSESS THE HAZARDS

What is the risk level? E= Extreme, H= high, M= moderate L=Low E/H/M L SEE YOUR SUPERVISOR AND/OR COMPLETE/ UPDATE SAFE OPERATING PROCEDURE

4.MAKE THE HAZARD SAFE

Are all hazards removed or at a low risk level? Where needed have I update the Safe Operating Procedure for this task? Does this all feel right?

5.COMPLETE THE TASK SAFELY

DO NOT START THE TASK! COMPLETE A HAZARD REPORT AND SEE YOUR SUPERIOR OFFICIAL(S)

Preventive measures have been suggested in detail in chapter III on Health & Safety Management Plan prepared for Munsar Mine, MOIL Ltd.



Treatment, Control and Action Plan: (Refer Table 4) Control measures can reduce either the likelihood or consequence of the event or both. The control measures for all the above mentioned risks have been tabulated mentioning the existing controls, actions recommended, responsibility and the time frame within which action should be completed



Table 4 Risk management plan on management system based on observations

Munsar Mine Sl. No Critical Areas

Identification Observation of Expert Future Action Plan Responsibility Time Frame

Schedule

1 Management Policy 1.1) Health and Safety (H&S) policy expressed commitment to health & safety at all levels but all recommendations of Fifth Conference on Safety in Mines were not taken into account in framing the Policy. Policy was not circulated widely to create awareness amongst all.

1.2) Duties & responsibility were not assigned at different levels for monitoring execution of policy.

1.1.1 Health & Safety Policy to be circulated, displayed in mines both in English & Hindi to create awareness.

1.1.2 H&S Policy be reviewed and improved to specify all other issues as recommended:

– Management’s commitment for provisions of adequate funds to achieve objectives.

– Specify set up for execution.

1.1.3 Review progress for execution by Board of Directors & Tripartite body at intervals not exceeding 6 months.

1.1.4 Discuss Safety Policy in safety committee meeting for wider awareness.

Owner, Agent, Manager, Personnel Manager (PM)

Owner, Agent, Manager, Personnel Manager.

3 Months

3 Months



Sl. No Critical Areas Identification

Observation of Expert Future Action Plan Responsibility Time Frame Schedule

1.2.1 Duties & responsibilities to be assigned in consultation with officers, supervisors & workers’ representatives.

1.2.2 The assignment to be finalized in consultation with DGMS.

1.2.3 The assigned duties, responsibilities to be handed over to the personnel concerned in pocket book form in Hindi & English.

1.2.4 The assignment to be revised based on working experience.

2 Standing Orders for all emergencies

2.1 General action plan to be used in case of emergency at the mine has been framed and approved by DGMS.

Duty cards to be issued to all the members of the emergency organization mentioning their specific duties in the event of an emergency.

Agent/Manager/

Safety Officer (SO)

One Month





3 Accident/Incident reporting &

investigation including emergency medical procedures.

3.1 System of reporting & investigation as per statute existed.

3.2 System of reporting near miss and no-lost time injuries exists.

3.3 Data regarding financial loss per tonne not maintained.

3.4 Details of accidents to be discussed in Safety Committee meetings and VTC.

3.5 Emergency medical aid provided.

------

3.2.1 Standard Guidelines for reporting all accidents be framed & circulated to all concerned in English & Hindi.

3.3.1 Analysis of accidents/ near

miss with details of financial loss to be maintained & discussed in senior officers’ meeting.

3.4.1 Details of accidents to be discussed in Safety Committee meetings & in Vocational Training Centre for greater awareness.

3.5.1 Emergency medical

procedures to be circulated to avoid confusion during emergency.

-------

Agent, Manager

Agent, Manager, SO, V.T. Officer.

Agent, Manager, SO, Medical Officer In-charge

(Hospital)

-----

One Month

3 Months

3 Months





4 Employees Relation System

4.1 HR manual is not being maintained. 4.1.1 H.R. Manual to be developed in agreement between management & workers’ representatives.

4.1.2 Employees should be made aware of management’s role (Duty of care) vis-à-vis employee’s role.

Personnel Manager

Manager, Personnel Manager

4 Months

4 Months





5 Emergency Evacuation &

Communication procedures

5.1 Emergency evacuation route marked on plan.

5.2 Emergency plan & model standing order in the event of stoppage of main mechanical ventilator were framed as per DGMS Circular.

5.3 Communication from surface to underground has been provided through intercom & is satisfactory.

5.4 There is no Rescue Room at Munsar mine.

5.1.1 Emergency escape route to be maintained fit for easy/fast movement and free from any obstruction by pipes, rails etc.

5.1.2 Use of escape route to be made compulsory.

5.1.3 Emergency evacuation exercise (mock rehearsal) to be continued regularly.

5.2.1 Competence in use of fire extinguishers to be developed.

-

5.4.1 Exemption should be obtained from DGMS for utilising the services of WCL Rescue station or it should be ensured that all the equipment as mentioned in Schedule III {Rule 11(3)} of the Mines Rescue Rules, 1985 are maintained at the mine. At least five rescue-trained persons should be readily available at surface at any time (Rule 19 of Mines Rescue Rules, 1985)

Agent, Manager, SO

Agent, Manager, SO

Manager, SO

Manager, SO

-

-------

Owner/Agent/Manager

3 Months

6 Months

6 Months

6 Months

-

------

At the earliest





6 First Aid to the injured.

6.1 Upgrade First Aid stations 6.1.1 First Aid stations to be upgraded with provisions of First Aid Boxes complete with materials as per Third schedule, Mines Rules 1955, Rule 44(1).

Manager, Medical Officer, SO

Regularly

6.2 Upgrade First Aid Training; No first aid training was given during 2014.

6.2.1 First Aid Training to be improved by holding regular classes.

V.T. Officer

3 months

7 Training & Re-training of workers &

supervisory staff

7.1 Required numbers of trainers have been provided.

7.2 Inadequate training in proper installation of roof bolts.

7.3 Departmental as well as Contractor’s workers are being given refresher training as per V.T. Rules.

7.4 Lack of monitoring of performance of trained workers.

7.5 Lack of structured training

programme for development of safety awareness.

7.1.1 Training needs to be improved with the use of modern gadgets.

7.2.1 More emphasis is to be given to train the employees in proper installation of bolts.

---------------

7.4.1 System to monitor performance of trained workers to be introduced & maintained.

7.5.1 Refer recommendation 1.11.2 of 10th Conference on Safety in Mines & formulate structured training programme for development of awareness & increasing effectiveness of emergency response in case of fire amongst work persons, officials & management.

Agent, Manager

Manager, V.T.Officer

--------------

Agent, Manager, SO, V.T. Officer

Agent, Manager, SO, V.T. Officer

3 months

1 month

--------------

6 months

3 months



Table - 5

Mechanism Existing Control

Relevant Statute Proposed Procedure

Responsibility For action

Time frame

Improper Strata Control:

Failure to identify bad roof

Visual inspection by the Mining Mate and Mine foreman. Checking the sound of the roof using crowbar.

Conditions as per the DGMS permissions; Cir. No. 11 of 2009; No.3 of 2010 and DGMS Cir 06/2002.

Special training shall be given to the personnel involved in strata control by informing them about different types of rocks/strata behaviour encountered at Munsar mine. Outside expert agency may be engaged for instrumentation in the stopes.

Agent/Manager/ UG Manager

3 months

Improper loose dressing

SOP framed in Hindi. Gangman is trained and authorised for loose dressing in each gang of 5 workers. 2m long Crow bars provided.

Special training to all the Gangmen regarding joint planes/cleavages and planes of weakness by taking the services of the geologist. Ensuring deployment of trained personnel in absence of regular Gangman. Ensuring that fully charged cap lamps are issued to all the underground workers. Spare sharpened crow bars to be kept in tool room.

Asst. Manager/ Foreman/ Mining Mate

As & when required

Improper supervision Asst. Managers, Foremen and Mining Mates have been appointed

Reg. 39 Special training classes may be arranged on the subject of strata control for supervisors particularly foremen & mining mates, and feedback should be obtained on effectiveness of the training.

Agent/Manager/VTO

2 months






Time frame

Lack of proper equipment for erecting supports e.g. Mechanical Pneumatic Bolters.

Stoper machines are used for roof bolting; and

Reg.112 and Cir 11/2002

Adequate number of Automatic Bolters may be procured.

Owner/Agent/ Manager

6 months

Poor workmanship due to frequent change of members of supporting crew

Additional workers have been trained in roof bolting

Special training may be arranged for the supporting crew. New recruits shall be specially trained in strata control. Anchorage testing to be done as recommended vide DGMS Cir. 2 of 2009.

Agent/Manager/ UG Manager/ VTO

Continuous

Inadequate support design

Support design is based on earlier study of RMR and strata geo-mechanical properties. No fresh study/review done.

Fresh study/review of RMR & Strata to be conducted thro’ expert institutions like CIMFR. SSR shall be reviewed periodically considering the recommendations of Scientific study conducted by CIMFR.

Agent/Manager As & when required

Poor quality of support material

Quality material is procured from approved suppliers.

Reg.113 and DGMS Tech.Cir. (Approval) no. 11 of 2009 and Cir. 3 of 2010

Ensuring procurement of DGMS approved support material/ quality fulfilling DGMS standard where applicable shall be ensured. Validity period of the approved suppliers should be verified beforehand. To ensure quality, a team should be constituted for the purpose and they may periodically visit the manufacturing units wherefrom support material is being procured.

Agent/ Materials Manager/ Mine Manager

Continuous






Time frame

Frequent breakage of scaling bars, tools

Scaling bar is immediately replaced /welded whenever broken.

Reg. 118 and DGMS Cir 06/2002

Ensuring correct welding technique and monitoring the material quality of scaling bars through the quality control team. Provision of deflection ring on the scaling bars will add to the safety against sliding pieces along the rod while dressing the loose.

Agent/Engineer In-charge(Mech.) /Mine Manager

Continuous

Lack of proper system of reporting between statutory supervisors during shift changeover

Shift instruction register is duly maintained.

Reg. 46, Reg. 47 and Reg. 116,

Strict implementation of statutory provisions and ensuring proper recording of reports and conferencing with successor.

Manager/Asst. Manager/ Foremen/ Mining mates

Continuous

Loose dressing at faces where height is more than 3 m

Normally the height of faces is restricted within 3m. However, under special circumstances 3 m long scaling bars (Ballam) are kept in spare in underground workings.

Reg. 116 SOP should be framed for loose dressing at high faces. Strict observance of SOP. Deployment of trained and experienced personnel for loose dressing under the supervision of competent supervisors. Ensuring good illumination in such places. Stable platform may be provided for reaching the high faces.

Manager/Asst. Manager/ Foremen/ mates

As and when required.

Poor Supervision: Negligence/ lack of commitment

Regular meetings, feedback for controlling, monitoring and motivating by Manager and Assistant Managers is in practice.

Reg.42 & 43 of MMR 1961

Regular meetings to be continued and safety culture needs to be maintained to ensure the compliance of the statutory provisions and proper discipline amongst the permanent as well as contractual employees.

Manager/AM Continuous

Not having proper knowledge / experience

A fully equipped Group VTC at Munsar is providing training to mine workers to update the knowledge and enhance the skills.

Rule 5 of MVT Rules 1966

Right persons suiting to the requirement of the jobs should be selected /recruited. In addition to the statutory training and in-company training, supervisors should

Personnel Manager/VTO

2 months






Time frame

also be exposed to out-company training programs.

-Inadequate training Special training programs are organised for the supervisors at regular interval.

Trainers may be trained by outside agencies to improve quality of training.

Manager/VTO 3 months

-Shortage of supervisors Competent supervisors have been appointed and duly authorized by the Manager.

Reg.34, 36 & 113 Eligible departmental candidates may be motivated and encouraged to appear in the competency examinations.

Owner/Agent/ Manager

Continuous

Inundation: Non availability of proper garland drains

Garland drains have been provided for conducting the rain water away from the mine

Reg. 127 of MMR 1961

Adequate size and length of garland drain should be ensured and cleaning of existing garland drains to be continued at regular interval and especially before monsoon.

Manager/SO/ Foreman

As & when required

Non formation of drains around the mine entry

Drains have been provided to course entire rain water away from the mine entry.

Manager/ S.O

Periodically

Clogging of garland drains /Failure of surface garlands

Surface garland drains are cleaned regularly especially before monsoon and U/g drains are cleaned at regular interval.

Manager/SO Before monsoon

Inadequate pumping capacity

Pumps of adequate capacity have been installed below ground and sumps are regularly cleaned as per planning /schedules.


Sump capacity and pumping capacity is adequate which should be periodically monitored especially before monsoon season.

SO/Engineer (Mech.) / Foreman (Mech.)

As & when required

Poor maintenance of pumps

Pumps are being regularly maintained in good working order.

Pumps should be maintained properly especially during monsoon.

Engr. (Mech.) As & when required and during monsoon

Encountering sudden inrush of water from the drill holes made for roof

Adequate sump and pump capacity to face if such situation arises.


Arrangement of water hurdles should be made in all the underground levels. The water hurdle slots should be

Manager/S.O./ Asst Manager

As & when required and before






Time frame

support regularly cleaned and the hurdle plate should be kept at proper place near the hurdle. Mock drill for fixing the water hurdles should be done at least once annually especially before monsoon in every underground level.

monsoon

Inrush of water from punctured boreholes into current excavations

All the boreholes have been properly surveyed and sealed at the surface.

Surveyor shall give prior intimation regarding the proximity of excavations as and when the workings are near to the boreholes. Plugging or complete filling of borehole may be done or controlled drainage may be allowed subject to quantity of water.

Manager/ S.O/Surveyor

As & when required

Inrush of water due to cloud bursts, heavy rains

Constant vigil is kept during heavy rains so that action plan can be put in to operation immediately.

Reg. 127, MMR 1961 and Cir. 02/1978

A team of at least 5 persons should be formed who shall be at call during heavy rains. Mock rehearsal of monsoon contingency plan to be conducted and proper record of the timing to be maintained.

Manager/ S.O/ Underground Manager

As & when required

Training facilities inadequate: Non-existence of training schedule for skill development

A strategic training schedule has been prepared to cover 100% workers.


Specific training modules should be prepared as recommended by the tripartite workshop held in Dhanbad in 1999 for each and every operation/group of employees and training to be given as per the revised modules.

VTO/SO 3 months

Untrained trainers Trainers have not been duly authorized

Rule 19, Rule 23 of MVT Rules 1966

Experienced workers/fitters may be authourised as trainers and they should be trained as per the training requirements.

VTO/SO As & when required






Time frame

Infrastructure not to the requirement

Group Vocational Training Centre at Munsar is equipped with all the requisite accommodation, furniture and gadgets/training aids etc.


- - -

Non-existence of feedback/test

Feedback on the performance of trainee is obtained from the supervisors.


A Board should be constituted to evaluate the competence of trainees especially all the HEMM operators and regular checks should be conducted to test their driving/operating skill, knowledge once at least in every 5 years.

Manager/VTO 3 months

Shortage of skilled persons/ deployment of unskilled persons: Absenteeism Counseling is done with the

absenting employees and action is also taken against habitual absenting employees.

Reg. 42/183 of MMR 1961 (Duties of competent persons/officials)

Special motivational training sessions should be conducted periodically and scheme may be introduced for displaying the photo of the workers giving full attendance during the month. While doing manpower planning margin should be kept for expected absenteeism.

Owner/ Agent/Mgr/ VTO/Personnel Manager

As & when required

Training not done as per requirement

Training is given as per statutory requirement.


In addition to the training by local faculty at Munsar VTC, efforts should be put to train the workers by external competent agencies.

Owner/Agent/ Manager/ VTO

At the earliest

Manpower sanction not as per requirement

Required manpower has been sanctioned. In addition to the departmental manpower, contractual manpower is engaged as per

Reg. 39 (1)(a) Advance manpower planning to be continued. The existing employees may be motivated to take training and clear the exams being conducted by DGMS.

Agent/VTO As and when required






Time frame

requirement.

Examination for workmanship not done regularly

Supervisors are examining the workmanship during routine inspection of the mine no special system exists.

A system should be developed for Employees to be examined against aptitude and knowledge required for the job.

Agent/Manager/Engineer/VTO

6 months

Lack of safety awareness:


Codes of practice/SOPs have been framed in English as well as Hindi for all the operations.

10th Safety Conference SOP & COP for each and every contractual operation as recommended by the 10th National Safety Conference should be documented, explained and circulated to all concerned.

Agent /Manager/ S.O / HR Head.

As & when required

Improper/ inadequate training

Training is imparted at the Group V.T. Centre as required under the statute.

Rule 5 of MVT Rules, 1966

Employees should be trained and retrained using modern gadgets. Training methodology may be updated by use of simulators for training of HEMM operators.

Manager/VTO/ S.O.

As & when required

Improper communication Telephones have been provided below ground.

Recommendations of 10th Safety Conference

Proper maintenance of the existing communication system should be ensured to avoid interruption.

Agent/ Manager/ Engineer

As & when required

Inadequate publicity / Objective not explained

Posters have been displayed at conspicuous places.

Recommendations of First safety conference

Safety instructions on Public address system at the beginning of shift may be introduced. Policy & objectives of the company should be properly framed and explained to all concerned. ‘Safety is my responsibility’ card should be given to contractual employees also. More posters to be displayed at specific locations such as substation, mine entry, underground mine etc.

Manager/VTO As & when required






Time frame

Improper Surveying: Calibration of instruments not being done regularly

As informed, calibration of instruments is done at the facility available with OEM.

Reg.64 Actions taken by the management is satisfactory. Continuity should be ensured.

Manager/ Surveyor

As & when required

Surveying not done in time

Mine working is being surveyed in time.

Reg.61 Mine working should be surveyed and plans must be updated in time.

Manager/ Surveyor

Continuous

Explosive and Blasting: Not taking proper shelter SOP for blasting has been

framed and circulated to all concerned.

Reg.164 and DGMS Cir. 04 of 1996, DGMS permission letter conditions.

Blasting Card System should be meticulously followed. While taking shelter belowground two right angle bends would keep the people out of danger.

Manager/AM/ Foreman/Mate/ Blaster

Continuous

Possibility of blown through shots

When two faces are within 5 m distance, one face is fenced, only single face is advanced and a pilot hole of 2.4 m length is always kept advanced.

Reg.164 and Cir.06/1983

Separate code of practice for use of explosives should be prepared and copies to be issued to all concerned whenever any two working faces are approaching within 9 m. In case of faces being worked within 9 m of each other, the surveyor shall intimate the foreman In-charge of the shift who shall in turn give instructions in writing to the mate. For general information to the employees the position of such faces shall be shown on a notice board near the entrance of the mine and updated on daily basis.

Manager/ Surveyor/AM/ Foreman/Mate/Blaster

As & when required

-Not following safe blasting procedure

SOP for blasting has been framed in English as well as Hindi and circulated to all concerned.


SOP should be strictly observed. Instructions regarding examining and securing the roof and sides within the zone of influence (to be fixed by the Manager) after blasting, before

Manager/AM/ Foreman/Mate

Immediate






Time frame

permitting workers to enter the area of blasting should be issued to the blasters and supervisory staff.

-Untrained / unauthorised helpers

Authorisations have been issued to trained workers to perform the duties of blasting Mazdoor/helper.

Reg.156 Explosives are being issued only to competent persons upon written requisition signed by the Blasting in-charge. The system of maintaining the transit slip should be continued. Adequate number of persons should be authorised keeping in view the rate of absenteeism to avoid the deployment of unauthorised persons.

Manager/AM/ Foreman

Continuous

Use of MACHINERY:

Non-framing of SOP/COP for erection, installation, operation, maintenance, repair etc. of each equipment/each operation

SOP for various operations and maintenance of HEMM has been framed in English.

Reg. 172 of MMR 1961 SOP may be widely circulated in Hindi. Agent/Manager/SO/ Engineer

1 month

Slip/trip while entering or leaving equipment

Operators/mechanics are competent and trained. They are vigilant while entering or leaving the equipment.

Reg. 181 of MMR 1961 The height of initial step should be 400 mm or less above the ground and two points of contact should be possible at all times. Non-slip access surfaces should be provided, which may include non-slip coverings for ladder rungs.

Agent/Manager/Engr. In-charge

3 months

Caught between moving parts

All the moving parts are provided with fencing /cover and all the vehicles are provided with audio signal.

Reg. 174 of MMR 1961 The operator shall not operate the machine when persons are in such proximity as to be endangered due to moving parts of machinery and shall ensure that all guards provided in the

Manager/ Asst. Manager/ Engr. In-charge/ Operator

Regular work






Time frame

machines are intact. Sign Boards shall be displayed at conspicuous places mentioning safe distance to be maintained between 2 machines. Other control measures which have potential to reduce the probability of collisions include: pre-start alarm; speed limits; vehicle lighting which indicates vehicle travel direction; proximity detection devices; traffic rules which stipulate vehicles stop while pedestrians pass; ensuring steering control-response-relationship are always compatible; and physical separation of pedestrians and vehicles.

-Maintenance schedule not followed

Vehicles are being maintained by following a schedule of maintenance.

Reg. 171(1) of MMR 1961

The code of instructions furnished by the manufacturers in the matter of maintenance of various machinery/ vehicles and preventive maintenance schedule for each type of vehicle should be strictly followed.

Agent/Manager/Engineer

Regular work

-Violation of SOP/COP Copies of SOP in Hindi have been issued to all the operators and salient features of the same have been explained to them.

Jist of the SOP should be constantly displayed at conspicuous places. Copies of SOP in Hindi should be issued to all the contractual operators.

Manager/AM/ SO /Engineer

2 months

-Unauthorised operation of machinery

Only authorized operators are allowed to operate the machinery.

Reg. 176(1) of MMR 1961

Present system of authorisation should be continued in case of new recruitment /replacement. To prevent unauthorised driving arrangement should be made such that

Manager/ Engineer

2 months






Time frame

the ignition key and/or cabin key always remains with the driver/operator or with specifically designated competent person(s).

-Unskilled operators Departmental Operators are selected from amongst the experienced workers at the mine

Reg. 39 of MMR 1961 Deployment of competent/trained operators should be ensured. Their competency is to be evaluated by the Board constituted by the company. All operators shall undergo regular checks to test their driving/operating skill, knowledge at least once in every 5 years.

Agent/ Manager/ Engineer/ VTO

2 months

-Bypassing safety devices The vehicles are being inspected by the competent person at the beginning of each shift to ensure that all the safety devices are functional.

Reg. 181 of MMR 1961 At the commencement of every shift, the operator shall personally examine all the safety devices and shall not take out the machine for work nor shall he work the machine unless he is satisfied that the vehicle is mechanically sound and in efficient working order. The operator shall report any defect observed, immediately to the manager, engineer or other competent person. Record of the test should be maintained in a bound paged book with special mention of condition of the safety devices. Surprise checks should be carried out and appropriate action should be taken against the person violating the guidelines.

Engineer / All operators

Immediate






Time frame

Extremity caught in between while transporting hand held machinery

SOP for carrying material has been framed in Hindi and being implemented. Workers are instructed to be careful while transporting the hand held machinery into the stopes/faces.

Reg.174(2), (3), (4) & (5),

During initial and refresher training of the operators/helpers, safe procedure for carrying hand held equipment should be demonstrated. SOP should be displayed in Hindi at conspicuous places below ground.

Asst Manager (AM) / VTO/ All operators/ helpers

As & when material is carried

Hit by compressed air hose pipe due to bursting or decoupling from the hose nut/clamp

Approved type of quality accessories and hose pipes are used and daily inspected by the fitter for looseness or any other defect.

Reg. 173 of MMR 1961 Every time before opening the compressed air supply, the hose fittings should be checked for tightness. Hose pipes and other attachments should be periodically replaced.

Manager/ AM/ Engineer/ Foremen/ Mining Mate

Regular work

Hit due to uncontrolled movement of air leg.

Air leg is inspected at the beginning of the shift by the fitters and defective air leg is not used for drilling.

Men and material winding in vertical shaft : Improper maintenance of the winding accessories

Proper maintenance and checks Daily, weekly & Monthly) are being exercised.

Reg. 91 of MMR 1961 System is satisfactory. To be continued. Manager/ Engineer

Regular work

Incorrect signaling/non observance of code of signals fixed by the manager

Signals received from the underground banksmen are confirmed by the master banksman at the pit top provided with Telephone to ensure correct signaling.

Reg. 83 of MMR 1961 System is satisfactory. To be continued. Manager/ Engineer

Regular work

Fall of the cages due to rope failure

Daily, weekly and monthly rope examination is done regularly by competent persons and

Reg. 88 of MMR 1961 System of examination of the winding rope is satisfactory. To be continued.

Manager/ Engineer

Regular work






Time frame

electromagnetic rope test is also carried out at 6 monthly intervals.

Uncontrolled movement of cages due to brake failure

Two braking systems provided and examination & testing of the brakes are done regularly by competent persons.

Reg. 84 of MMR 1961 System of braking is satisfactory and examination & testing of the brakes to be continued.

Manager/ Engineer

Regular work

Over-winding when persons are inside the cage

Reliable depth indicator and automatic contrivance (limit switch/Over speed trip switch) are provided showing the cage position and the same are regularly (daily and weekly) checked for effectiveness.

Reg 84 of MMR 1961 System is satisfactory. To be continued.

Manager/ Engineer

Regular work

Fall of cages due to failure of rope attachments in headgear

Properly designed and certified attachments are provided. Automatic slack rope safety device provided.

Reg. 84 of MMR 1961 Keps should be checked daily by a competent person to ensure smooth operation and record to be maintained thereof.

Manager/ Engineer

As & when changeover is done

Cage movement due to failure of sheaves

The sheaves are inspected by competent person daily and weekly and findings are recorded in log book. Sheaves are checked, cleaned and greased weekly. Properly designed and certified sheaves are procured and fitted.

Reg. 80 of MMR 1961 System is satisfactory. To be continued.






Time frame

Slipping and falling while entering/leaving the cage

The cages have been provided with gates and the same are ensured to be in position by the banksmen before signaling the cage operation.

Reg. 84 & 93 of MMR 1961

To ensure the safety of persons riding in the cage, the following monitoring shall be required.

Cage doors shall be monitored for closing and locking before the winder can be moved.

Platform gate doors shall be monitored for closing and locking before the winder can be moved.

Platform gate doors shall not be operable unless the cage is positioned at the landing.

Cage doors shall not be operable once it has moved away from the landing. They should be interlocked with WE.

Duties of Persons riding or working in shafts as mentioned in Reg. 93 of MMR 1961 should be displayed in Hindi at conspicuous place at the pit top.

Manager/ Engineer

Regular work

Unauthorised or unskilled driver

Adequate number of competent first class WE Drivers have been authorised.

Reg. 78 of MMR 1961 Advance planning should be done for future requirement. Departmental candidates may be trained and encouraged to appear in the DGMS W.E. Driver’s competency examinations.

Manager/ Engineer

As & when required

Major incident caused by distraction of driver, due to noise from winder, fan or other noise

Winder is maintained in good working order. The driver is provided with enclosed cabin.

Reg.84 of MMR 1961 Arrangement is satisfactory. To be continued.

Manager/ Engineer

-






Time frame

Major incident caused by distraction of driver due to People

The driver is provided with enclosed cabin and only authorised persons are allowed to enter the winding engine room.

Reg. 94 of MMR 1961 Arrangement is satisfactory. To be continued.

Manager/ Engineer

-

Major incident caused by driver fatigue

Sufficient numbers of W. E. drivers are appointed. No driver is required to perform over time duty.

Advance planning should be done for future requirement. Departmental candidates may be trained and encouraged to appear in the DGMS W.E. Driver’s competency examinations.

Agent/Manager As & when required

Struck by burst hydraulic hose (inside the WE room)

Quality hoses are procured from authorised suppliers and during daily/weekly inspection, the fitters are checking the hoses and unauthorised entry is restricted in WE room.

Reg. 174 of MMR 1961 To continue the following actions:-

Only hoses of approved quality to be used.

Daily & weekly checks / Inspection by fitter.

Low pressure & flow control valves to be provided.

Access control to machinery area.

Manager/ Engineer

As & When required

Caught in moving machinery (inside the WE room)

Guards have been provided on all moving parts and authorised access in the W.E. Room.

Arrangement is satisfactory. To be continued.

Engineer/ Elect. Supervisor

Regular work

Slipping/falling due to oil/grease on floor (inside the WE room) or while entering cabin

Floor is maintained clean and free from spilled oil/grease. Non-slip steps provided in the cabin.

Reg. 80 of MMR 1961

Electric shock while fault finding on live panels (inside the W.E. room)

Approved type test equipments have been provided. Only trained and authorised competent

Reg. 19 of CEAR 2010






Time frame

persons are deployed. Circuit diagrams are also available.

Transportation of material- Haulage:- Struck by Tub or material, due to Rope failure

Regular inspection and regular re-capping is being done. Interconnected run away switch and stop block fitted. Drag/backstay is compulsorily attached to the ascending tub.

Reg 95, Reg 97 and Reg. 101 of MMR 1961

Record of inspection of ropes of all the haulages should be properly maintained. Drag must be provided on all ascending tubs. Sufficient number of drags should be kept available at the pit top and pit bottoms. The run-away switch should be periodically tested and proper record should be maintained.

Manager/AM/ Engineer

Regular work

Struck by Tub or material, due to failure of Tub coupling, drawbar or slings

Regular inspection and timely replacement of the coupling is done

Reg. 97 of MMR 1961 Record of the weekly examination of the state of every buffer and drawbar of every tub, safety catch, coupling chain and other attachments shall be maintained in a bound paged book. The tub couplings should be replaced at every 5 years interval and proper record shall be maintained

Manager/ Engineer

Regular work

Struck by Tub or material, due to failure of brake

Brakes are regularly tested Reg. 101 of MMR 1961 Record of daily examination of brakes and other safety appliances of each haulage by competent person shall be properly maintained.

Manager/ Engineer

Regular work

Unexpected movement of Tubs at pit top or bottom stations

Proper signaling arrangement is provided and the haulage is operated only after getting clear signals. Sprags to the wheels/Chain on track is put to arrest movement of tubs on their own

Reg 95 of MMR 1961 Code of signals to be strictly observed and operation of telephones between the pit top and bottom in working order shall be ensured every time.

Manager/ Engineer

Regular work






Time frame

Unauthorized personnel gaining access to controlled areas

Only authorized persons are allowed near the haulage room or near the track

All the haulage rooms should be provided with a proper gate which can be locked to prevent entry of unauthorised persons.


3 months

Derailment caused by poor track conditions:

Only 30 lb rail section is used for laying of tracks and Tracks are maintained in good order

Reg. 101 of MMR 1961 The record of weekly examination of every haulage track and the safety contrivances provided thereon shall be properly maintained. Portable tub re-railers shall be provided and kept at suitable locations.


Regular work

Derailment caused by obstructions (fall of ground, badly loaded scrap and material)

Adequate precautions are taken while transporting scrap or material to surface.

Reg. 102 of MMR 1961 The record of weekly examination of every haulage track and travelling roadway shall be properly maintained.


Regular work

Derailment caused by Badly loaded material (Timber, Cement, Steel, pipeline etc) from surface

There is separate trolley for transportation of timber/pipelines etc.

Sufficient number of such trolleys should be provided. Material should be lowered under the supervision of competent person. Persons likely to be endangered should be warned before lowering such material.

Asst. Manager/ Engineer

As and when material is lowered.

Derailment caused by poor tub condition/non provision of Safety catch

Tubs have been properly numbered and are being maintained regularly

Reg. 97 of MMR 1961 Proper record of each and every tub should be maintained and its attachments should be replaced as and when required.

Manager/ Engineer

Regular work

Derailment caused by track switches

All the switches are maintained periodically

Arrangement should be made to provide levers for the operation of all the switches. Fixation of tie rods should be ensured to the tail of all the switches.

Manager/ Engineer

Regular work






Time frame

Injured while reloading material in incline shaft

Re-loading material on the inclines is done under the personal supervision of the mining mate

Tracks along the inclines should always be maintained in good order and practice of re-loading under the personal supervision of mining mate should be continued.

Manager/ Engineer

As and when required

Injured while riding on Tubs

No persons are allowed to travel on tubs and this is ensured by strict supervision

Reg. 97 of MMR 191 Present system is satisfactory. To be continued.

Manager/ Engineer

Regular work

Fires: -Fires in diesel operated machines

Fire extinguishers have been provided on all equipment.

Reg. 121 In addition to other precautions being taken, AFDSS should be provided on all HEMMs as recommended by DGMS (Tech) Cir. no. 10, 2004.

Manager/ Engineer

3 Months

-Electrical fires Fire extinguishers have been provided in sub-stations and at other important locations including workshop, stores, etc.

The practice of re-filling the fire extinguishers should be continued.

Elect. Engineer/ SO/ Supervisor

Weekly

-Fire during gas cutting

Adequate precautions are being taken during gas cutting.

Reg. 119

Fire extinguishers of desired type should be provided at the site, to be used in emergency.

Manager/ SO As & when required

Before starting the gas cutting operations it should be ensured that water or other arrangements for dealing with fire are in place.

AM/SO/ Engineer/ Foreman

-Spilled off lubricants Floors likely to be affected by the spillage of lubricants are being cleaned regularly.

Reg.119 Special attention should be given to the areas where the spillage of lubricants is expected to be high. Cleaning should be ensured to avoid accidents. Regular checks should be ensured.

SO/ Engineer/ Foreman

As & when required

Transportation of ROM from the ore pass to the pit bottom:






Time frame

Hit by ore piece during ore pass gate operation using improper tools/standing at incorrect position.

SOP for withdrawal of ore from the ore pass framed in Hindi and circulated. Suitable gates provided to hold back the ore column. Workers have been instructed to stand away from direct line of the ore pass. Long poking rods are provided for every ore pass.

Reg. 97 & 98 SOP may be displayed at conspicuous places belowground (rest shelter etc.). The poking hole may be provided with hinged key-hole lid arrangement. The poking rod may be fitted with deflection ring. Lighting should be provided at every ore pass.

AM/Foreman/ Mining Mate

Regular work

Slip/trip due to excess water from the ore pass due to sand stowing in adjoining area.

All the haulage and travelling roadways are examined weekly by competent person (Foreman). Weep holes have been provided to the cross cut walls. Drains of adequate cross section made along one side of the crosscut.

Reg. 102 of MMR 1961 Regular cleaning of the cross cut drains should be ensured. Spilled material should be regularly cleaned to avoid formation of slippery ramps besides the track in front of the ore pass.

AM/Foreman/ Mining Mate

Regular work

Slip/trip due to Inadequate height of ladder at the manway.

Height of ladder projected above mouth of man-way as directed by DGMS

Height of ladder at least 1 m above stope floor should be ensured in all cases.

AM/Foreman Regular work

Fall of persons in to the ore pass

Ore pass is always kept above the stope floor level

It must be ensured every time that the height of ore passes to be always above the stope floor level. Standing order should be framed to stop unloading material in the ore pass whenever it is at the floor level.

Manager/AM/ Foreman

Regular work






Time frame

Injury during re-railing of derailed tubs

All the tubs are provided with safety catch to prevent accidental tipping. Tracks are maintained in good order. Workers have been instructed to use long balli for re-railing of tub.

Reg,97 of MMR 1961 Safety catches of both sides of the tub should be properly secured before moving the tubs. Workers should be shown demonstration of correct procedure for re-railing of tub during vocational training. Portable re-railers may be provided and kept with the loco.

Engineer/ Foreman/

Mining Mate/ VTO.

Regular work

Hit due to extremity caught in between two tubs

SOP framed in Hindi for manual tub pushing mentioning maintenance of at least 10m distance between two tubs.

Distance of at least 10 m must be maintained between two tubs. Proper signal & verbal warning should be given to the persons likely to be endangered due to the moving tubs.

Rolling stones while transportation or tipping of tubs at the OCF gala

Adequate precautions are taken and the work of unloading of tubs at the OCF gala is carried out under the supervision of mining mate

Adequate lighting should be ensured at the OCF gala after day light hours. Boulder size should be restricted at the stope itself. Proper chain should be provided and used to prevent overturning of the tub at the gala.

Foreman/ Mining Mate

As and when Tubs are tipped at the gala

Poor tub/track maintenance

Tub and track maintenance is done regularly.

Reg. 102 Adequate lighting should be ensured all along the haulage road. Drainage along the haulage road should be regularly cleaned preventing accumulation of water. Track should be laid as per the grade line given by the surveyor. Numbering of tubs should be done and properly recorded.

AM/Elect. Engr. /Foreman/ Mining Mate.

Regular work






Time frame

Environmental Issues: Lack of monitoring of subsidence movement and not taking timely remedial measures to avoid loss of life & materials, effective plugging of cracks etc.; mine entries are not above HFL.

Subsidence monitoring is done on the basis of physical inspection only of water bodies, structures etc. Management informed that till date no subsidence movement has been noticed. The underground mine voids are filled with sand by stowing thereby minimizing the occurrence of subsidence. Pit top is above HFL with proper drainage arrangement. Study on subsidence has not been conducted.

EP Act, EC condition. a)Monitoring of Subsidence should be continued on regular basis. b) Study of subsidence should be carried out and report should be submitted to MOEF & DGMS. c) De-pillaring & thickness of safe barrier should be decided & carried out in consultation with and obtaining prior approval of DGMS.

Agent, Manager, Environment

Engineer

Study of Subsidence = 6

months. Rest regular

works.

Lack of stabilisation of existing OB dumps and backfilling.

Munsar UG is an underground mine but earlier opencast mining was done but voids have not been filled and presently being used as water reservoir. Sub-grade dumps are being re-handled to recover low quality ore. As a result the dump stability is disturbed. However dump height is

EP Act, EC condition. a) Long-term plantation & maintenance programme. b) Study & continuous monitoring of slope stability of reject dumps and sub-grade dumps. c) Safeguarding existing plantation by suitable planning of fencing, watch & ward etc. and implementation thereof.

Agent,, Manager, Environment

Engineer

6 months






Time frame

around 10-20 m. Part of reject dumps has been planted. However, plantation on sub-grade dumps is being damaged. No study of dump stability has been done.

Catch drain, garland drain and siltation ponds have not been constructed of adequate capacity and/or are not cleaned/de-silted regularly.

Catch/garland drains have been constructed to channelize surface run-off during monsoon. No siltation pond has been constructed.

EP Act, EC condition. 1. Catch/garland drains should be maintained of adequate dimension to take peak load. 2. Cleaning & desilting works alongwith other measures required periodically. 3. Construction of required capacity siltation ponds for surface run-off.

Manager, Environment Engineer

On regular basis

Inadequate quantity of plantation done than required (as per EC condition) for dust absorption, noise barrier and slope stabilisation.

Afforestation is being done on waste dump area and around infrastructure & township within lease area. Total plantation done at Munsar mine till 2014-15 is around 78000 nos. on 148 ha (approx). Species planted are Teak, Neem, Bamboo & Karanj. However survival rate is less as observed on eye estimation.

EP Act, EC condition. a) Long term maintenance including fencing, watch ‘n ward for better survival & growth of plants. b) Geo-textile matting/ grass plantation should be done on critical dump slopes. c) Plantation should be done with more varieties of species including Mango, Jamun, Tamarind & other naive species having large leaf foliage and dense canopy. d) Long-term plantation programme should be formulated around siding, dumps, around abandoned opencast pits & newly installed infrastructure (shaft, office, winder house, substation etc).

Agent, Manager, Environment Engineer

Progressively throughout

mine life






Time frame

Mining activities are causing water pollution due to discharge of effluent.

UG mine water is pumped to surface and fully used in sand stowing and dust suppression. . Abandoned mine pits are acting as water reservoirs facilitating restoration of groundwater table. No effluent is discharged outside lease area without treatment. Workshop ETP not provided as HEMMs are mostly of contractors and are washed outside mine premises. Domestic effluent is treated in septic tank & soak pit.

EP Act, EC condition. i) Oil & grease trap should be installed at contractor’s premises to treat washing ramp effluent. Effluent should be tested before & after treatment. ii) It should be ensured that in any case untreated effluent should not be discharged to outside nalla/ river.

Agent, Manager, Environment

Engineer

Regular work

Lack of storage & disposal of hazardous wastes.

This mine primarily being an UG mine, no hazardous waste is generated in Munsar mine except small quantity of used oil which is stored in barrels and either re-used in machineries in workshop or given to registered recyclers thro’ MOIL HQ.

Hazardous Wastes Rules.

1. There should be no oil spillage on ground anywhere in mine premises. 2. Used oil should be either re-used within the mine and/or given to recyclers on regular basis as per statute.

Manager, Environment Engineer

Regular work






Time frame

Stoppage of Mining activities and production of mineral for not obtaining valid Environment Clearance (EC).

Munsar mine has valid EC for mining lease area 149.06 ha with production capacity of 4166 tonne per month issued by MOEF vide letter no. J-11015/413/2607-IA.II(M) dated 26.12.2007. Six-monthly reports on compliance of EC conditions are submitted regularly to MOEF.

EP Act, EIA Notification, 2006

The conditions given in EC should be complied in a time-bound manner to avoid penal action. Mandatory six-monthly report should continue to be submitted to MOEF on regular basis.

Agent, Manager, Envt. Engineer

6 months

Stoppage of Mining activities and production of mineral for not obtaining valid Consent to operate (CTO) from SPCB.

Munsar Mine has valid CTO upto 30.6.2015 issued by MPCB under Air & Water Acts obtained vide letter dated 15.1.2013. Application for renewal of CTO has been submitted to MPCB.

EP Act, EC condition Matter should be vigorously pursued with MPCB for grant of renewal of CTO before 30.6.2015 and compliance of all EC & CTO conditions should be ensured. Manager, Envt

Engineer Immediate

Inadequate and inefficient treatment of sewage due to not constructing Sewage treatment plant, ETP & tailings pond.

Septic tank-soak pit system is installed in the colony. Workshop ETP not provided as this is an UG mine & most of the HEMMs belong to contractors and they are washed outside mine premises. Mine water from underground is pumped to sand stowing plant at surface for re-use in sand

EP Act, EC condition a. STP for colony should be installed. b. Regular monitoring of effluent/mine water quality to be ensured continually. c. Water potability test should be done for bore-well water supplied to office, workplace & colony for drinking purpose (as per IS:10500).

Manager, Engineer, Envt. Engineer

6 months






Time frame

stowing & dust suppression. Mine water is quarterly sampled and tested for quality. No mine water is discharged outside without treatment. Bore-well water is supplied to office, workplace & colony without further treatment and without potability test (as per IS:10500 for drinking water).

Inadequate nos. of air quality monitoring stations resulting in lack of information on air pollution occurring due to mining & plant activities.

4 nos. ambient air quality monitoring stations have been established at Munsar Mine (Mine pit, Mine office, Staff colony & Mine Hospital). Quarterly air monitoring at these locations is being done by external agency and report is sent regularly to MPCB. Personal dust monitoring is carried out on workers at UG six-monthly. However, Fugitive dust emission at workplace (fixed point dust monitoring) on surface & UG workplaces is not monitored as such high dust generating areas are not identified.

EP Act, EC condition a) Fugitive dust emission on surface should be measured at major dust generating areas viz. dumper tipping point, siding, haul road, ore transport road, etc. At UG, workplaces for drilling, mucking etc. should be monitored with fixed point dust monitoring. b) Gravimetric type dust samplers should be used for fixed point dust measurement. c) Personal dust monitoring should be done on surface workers also after identifying high dust areas.

Manager, Envt Engineer

Regular work






Time frame

Dust pollution due to lack of control on fugitive emission and inadequate dust suppression arrangement.

Blasting – The face is wetted by water before and after blasting in the UG to control the dust generation.

Drilling – Wet drilling is being practiced at underground.

Haul roads & mineral transportation roads are sprinkled with water by 1 no. water tanker only which is found inadequate.

EP Act, EC condition. i) Permanent dust suppression system in the form of fixed water sprinklers should be installed at critical road junctions, Siding & other critical points. ii) 2 nos. water tankers should be simultaneously deployed for effective dust suppression on surface. iii) More no. of trees with big canopy & large leaf foliage should be planted around new installations (shaft, office, winder house, sub-station etc.). Workers exposed to high dust zones should mandatorily wear dust masks.

Manager, Engineer,

Envt. engineer 6 months

Lack of control on noise pollution/level as per statute and workers not wearing ear plugs/muffs.

Noise monitoring is done at 4 points viz. UG pit, haul road, jack hammer drill & Ventilation Fan on quarterly basis by an external agency. As per quarterly noise report, noise level at jack hammer drill (UG) has exceeded 100dB(A) in Sept & Dec.’2014. Noise mapping to establish high noise areas is not done. Noise dosimetry to measure personal noise exposure is not done. Ear plugs/muffs have been provided by the management to the workers

EP Act, EC condition. i) Sound level meter should be procured and used to measure noise fortnightly and for noise mapping. ii) Reduction of noise generation at source should be first tried at Jack hammer drill & ventilation fan, thro’ suitable maintenance & modification. iii) Wearing PPE should be made mandatory for high noise areas. Workers should be properly trained about use & need of PPEs. iv)Plantation to be done along infrastructure to serve as a noise barrier.

Manager, Envt engineer

3 months






Time frame

as informed but are not used by workers working at high noise zones like jack hammer drill, ventilation fan etc.

Workers exposed to dusty environment are not wearing dust masks and being vulnerable to contracting dust related diseases.

As informed, dust masks have been provided to personnel working in dusty areas. Personal dust monitoring of workers is carried out at underground on six-monthly basis. No dust monitoring of workers on surface.

Hospital/dispensary is run by the mine for regular health surveillance. Periodic Medical Examination (PME) of all workmen working in the mines is being done at occupational health centre but not as per statute. PME of contractual workers has not been done till date.

EP Act, EC condition, DGMS Cir.01/2011

1) Action should be taken to ensure that workers religiously use dust masks at high dust areas. 2) Periodic Medical Examination of workers exposed to high dust level should be done at shorter intervals viz. 6 months. 3) Training on safety & health aspects to be imparted on regular basis. 4) PME of contractual workers should be done at 3 years’ interval.

Manager, Envt Engineer

Regular work

Occupational Health: Occupational health hazard- Unfit for duty

Initial and periodical medical examinations of all the departmental as well as contractual workers are done as per statute.

Mines Rules 1955 & Recommendations of 10th Safety Conference.

IME/PME as per the recommendations of 10th safety conference should be continued and computerized record should be maintained.

Manager /MO/SO

As & when IME/PME is done






Time frame

Electrical Shock or short circuit:

Bypassing electrical protective devices

Electrical equipments are being inspected by competent person every day.

Reg. 115 of CEAR 2010 Steps should be taken to ensure that equipments become inoperative in case of any protective device are bypassed.

Manager/ S.O./ Engineer/ Elec. supervisor

Continuous

Unskilled electricians/helpers

Electricians and helpers have been appointed.

Only competent electricians with requisite certificates should be appointed. Orientation courses for skill development of the existing electricians and helpers should be conducted periodically.


Installation of gate end boxes and switches in unsafe place / condition

SOP for installation of electrical equipment has not been framed in Hindi.

Reg. 104 and Reg. 109 of CEAR 2010

SOP for safe installation of gate end boxes and switches should also be framed in Hindi and circulated amongst the concerned. While selecting the site for installation of gate end box, switch and other equipment safety aspects should be considered along with conditions of SOP.

AM, Engineer & Elect. Supervisor


Inadequate support of power cable

Power cables are supported by clamps of adequate strength

Reg. 106 of CEAR 2010 Existing system should be continued. However, care should be taken to strictly avoid hanging of telephone cable and power cable on the same clamp/hook.


Temporary joints in lighting cable

Lighting cables whenever required are extended with permanent jointing.

Reg. 105 of CEAR 2010 No temporary joint should be allowed in lighting cables.


Immediate






Time frame

Unauthorised Entry Near Hazardous Operations:

- Trespassing by villagers to avoid long route Intention of theft

Round the clock security is exercised by departmental security guards.

The mine area should be suitably fenced. Patrolling by the security staff to be increased to prevent trespassing by villagers. Caution notices in local language should be posted prohibiting unauthorised entry.

Manager/ Security officer

Continuous

Curious onlookers around the Machines

No outsiders are allowed to enter or remain in the vicinity of HEMM.

Counseling should be done to the villagers explaining the dangers associated with operation of machinery and the mining activity in general.

Manager/ Security officer

Regular work

Employment of adolescents

No person (departmental as well as contractual) is employed without Initial Medical Examination.

Sec.45, Mines Act 1952

Action taken by management in this regard is satisfactory.

Medical Officer/ SO/ Personnel Manager

-------

Unauthorised deployment Contractors have been instructed in writing to immediately bring to the notice of the management any changes in the manpower by him to work in the mine.

Rule 77A, Mines Rules1955, Sec.48, Mines Act 1952

All the contractor’s workers should be issued photo identity cards and surprise check should be carried by senior officers to ensure possession of the cards and presence of authorised persons only.

Manager/ PM/ SO

Continuous

Family members entering in the mine along with workers on duty.

Every entry is being checked by the guards posted at the check posts.






Time frame

Manual sizing, sorting and stacking of ore

Strains and sprains from lifting loads improperly or from carrying loads that are either too large or too heavy

On site supervisors instruct the workers against overloading the basket.

Shifting manual operation to mechanized operation in phased manner.

Periodical training of the workers showing correct procedure for lifting of loads.

Site preparation to be such as to restrict manual load carrying lead distance within 10m.

Manager/AM/ Mine Foreman

Regular work

Hit due to flying pieces Boulders are separated and manually broken at a distance away from the other workers.

SOP for boulder breaking to be prepared in Hindi.

No person to remain within a distance of at least 5m from the breaker.

Portable folding screen to be used around the boulder being broken.

Use of PPE viz approved type Safety goggles, Shin guard must be ensured.

Manager/AM/ Mine Foreman/ Mining Mate

During boulder breaking

Extremity being caught in between objects

Cotton hand gloves are issued to the workers.

SOP for sizing of ore should be framed in Hindi.

Workers should be periodically trained with demonstrations of correct ore breaking procedure.

Use of PPE to be ensured viz approved type safety goggles/hand gloves.

Manager/AM/VTO/ Mine Foreman/ Mining Mate

Regular work.

Fall of material not stacked properly including rolling stones

Stack height is restricted to 2m. Stacking of ore is done under competent supervisors.

SOP to be framed for stack preparation in Hindi.

Use of hand gloves to be ensured.

Manager/ AM/ Mine foreman/ Mining Mate

Regular work






Time frame

Fall of person on level ground or from wooden platform while loading the truck

Place for loading is kept clean and obstruction free.

SOP should be framed in Hindi for manual truck loading operation.

Implementation of SOP to be ensured.

Workers to be trained at regular interval with demonstration in correct truck loading procedures.

Manager/AM/ Mine Foreman/ Mining Mate

Regular work

Manual Loading into Trucks

Run Over by Truck/Jeep The loading operation is carried out under the constant supervision of loading in-charge


SOP should be framed and issued to the truck loading in-charge at the siding.

Boards in Hindi/Marathi prohibiting unauthorised entry should be displayed at conspicuous places.

Manager/SO/ VTO

One month

Adverse effect on Health due to airborne dust

Water is sprayed as and when required. PME of all the contractual persons is conducted as per statute.


Spraying of water at regular interval should be ensured.

Airborne dust Survey should be conducted periodically with approved type of gravimetric dust sampler and proper record should be maintained.

Competent person in-charge of siding

Regular work


Prioritization of risks:

Following is the risk ranking based on risk score. Risk which have a score of 70 and

above may be taken up on priority and suggested actions may accordingly be initiated. As

per the qualitative risk assessment vide Cir. MAMID 01 also, these risk (70 & above) come

under extreme/high risk.

Table - 6

Sr. No.

Description of Hazard Risk Ranking Remarks

1. Improper Strata Control I Extreme

2. Use of Machinery I Extreme

3. Men and material winding in vertical shaft II Extreme

4. Explosive and Blasting III High

5. Poor Supervision III High

6. Unauthorized entry near hazardous operations

IV High

7. Environmental issues V Moderate

8. Transportation of material- Haulage V Moderate

9. Shortage of skilled persons/deployment of unskilled persons

V Moderate

10. Fires V Moderate

11. Training facilities inadequate V Moderate

12. Transportation of ROM from the ore pass to the pit bottom

V Moderate

13. Improper surveying VI Low

14. Manual breaking and sizing of ore VII Low

15. Manual loading of ore into trucks VII Low

16. Lack of safety awareness VII Low

17. Inundation VII Low

18. Electrical shock or short circuit in the use of electrical equipment/machinery

VII Low

19. Occupational health VIII Low

Risk Assessment, Safety & Health Management Plan Munsar Mine, MOIL, Ltd.

Kratin Solutions Pvt. Ltd, Nagpur 119

Health & Safety Management Plan for contractual workers:

Contractors have been engaged at Munsar Mine for mechanized handling of dump

ROM. Though the contractors’ workers are being trained at VTC they lack the

knowledge about the safety rules & regulations to be followed while working in the

mine.

Basic reasons for chances of accident of contractual workers are summarized

below:

1) Wages are proportional to the production of ore.

2) Incentive on increased output due to which at times safety is neglected.

3) Minimum awareness of Traffic Rules etc.

4) Not deploying the trainees under the proper supervision of a competent trainer.

5) Poor maintenance of machinery (much below the requirement).

To avoid accidents to contractors’ workers the mine management will have to be

more vigilant and strict in complying with the safety rules in work places. Awareness

regarding safe practices among the persons working in the mine is a must.

The detailed Safety Management Plan for contractual works of the Munsar mine of

MOIL Ltd. is given in the tabular form as below:


Table–7

Health & Safety Management Plan for contractual workers

Sr. No.

Critical Areas Observations Future Action Plans Responsibility Time Frame

Schedule 1) Occupational Health Surveillance Initial Medical Examination

of all the contractual employees engaged in mining job is conducted before entering their names in the Form B register.

i) Periodical Medical Examination including occupational safety and health surveillance of all the contractual employees shall be conducted by an expert agency once in at least three years or lesser interval.

ii) Identifying group of contractual persons engaged in areas prone to generate air borne dust.

iii) Conducting PME of such persons at an interval of 6 months.

iv) Proper computerised record of PME of the contractual employees should be maintained.

Agent/Manager/SO/ Medical Officer

3 months

2) Training to all contractual workers engaged in the mine premises

Contractor’s workers are being trained at Group VTC Munsar.

v) Before commencement of work against the work order contractor shall submit to the manager a list of his workers/ supervisors to be trained as per VT Rule.

vi) A list of trained workers already available with the contractor shall be furnished

Manager/ VTO/ Contractor As and when required.

Risk Assessment, Safety & Health Management Plan Munsar Mine, MOIL Ltd.


Sr. No.


Schedule to the manager.

3) Record in Form -B Record of all the contractual employees is being maintained in Form- B.

Manager shall ensure that the records of all contractors’ workers are maintained filling in all the required information in company’s Form B register as per statute and all the contractor’s registers should be kept in mine manager’s office.

Manager/ Personnel Officer/Contractor

Regular

4) Supervision Supervisors are appointed by the contractor to supervise work and SOPs have been distributed to the concerned.

To ensure that contractor’s workers follow the safety rules, regulations & guidelines, inspection by departmental competent statutory personnel should be ensured.

Agent/Manager Regular

5) Issue of identity Card Identity cards have been issued to l contractor workers.

Contractor shall issue proper photo identity cards to all workers under him and shall not employ any new worker without permission from manager. Surprise check should be conducted by Sr. Officials of the mine to verify the possession of Photo Identity cards by the persons.

Manager/ PO/ VTO Regular

6) Attendance/ Working Hours/ Rest day

Work is being carried out as per the statutory provisions applicable.

i) Attendance of contractor’s workers shall be recorded in Form C/D/E as per mines rules.

ii) Working hours shall be

Manager/ PO Regular



Sr. No.


Schedule limited to 8 hrs/day.

iii) Weekly day of rest shall be ensured.

7) Safety appliances Safety appliances (PPE) are being issued and used by underground contractual workers but their regular use by contractual workers deployed on surface needs to be enforced.

All workers shall be provided with safety appliances required for the job assigned to them and their use shall be ensured thro’ surprise inspection by senior officers.

SO/AM/ Foremen/

Mining Mate

Regular

8) Fitness Certificates and Road worthiness of vehicles

Contractual Vehicles are being checked to ensure their road worthiness by the engineer periodically.

i) Engineer shall ensure the checking of vehicles/ machines to ensure their fitness including provision of safety devices and proper record shall be maintained.

ii) Engineer shall recommend for issue of valid pass to the vehicles found fit.

iii) No contractor’s vehicle shall be allowed inside the mine premises without valid pass issued by manager.

iv) The Engineer will be overall responsible for daily, weekly checking and maintenance of contractor’s vehicle/ machinery.

v) Random check shall be made by engineer/ safety officers as regard to the provision/

Agent/ Manager/ Contractor/ Engineer

Regular



Sr. No.


Schedule working of safety appliances.

vi) If any vehicle is found not fit for use, the same shall not be allowed inside the mine unless the defect has been rectified and the vehicle has been certified to be fit by the mine engineer in writing.

vii) The time of incoming & outgoing of contactor’s vehicles in the command area should be recorded in a separate register at the check post.

9) Unauthorized driving/ riding Instructions have been issued not to allow any unauthorised person to drive/ ride any vehicle in mine premises.

i) Contractor shall submit the list of drivers along with the valid licenses for verification to the engineer and issue of authorisation by Manager. No such driver should be allowed without verification of licenses/ authorization.

ii) No helper/ any unauthorised persons shall be allowed to travel in tipping trucks. Trained trip man/ helpers shall be provided at the loading and unloading point.

iii) Manager shall take all appropriate steps to ensure

Manager/ SO / Engineer/ Security officer

Regular



Sr. No.


Schedule prohibition of unauthorised riding.

10) Loading areas: Face supervisors/A.M/foreman/Mate

Safe code of practice has been framed in Hindi.

They shall ensure that: i) Movement of workers and

the loading machine and truck operation is suitably fixed so that men and machine do not remain in the same area at a time.

ii) Pay loader operation zones and the parking sites of tippers for loading and waiting should be well defined and marked to avoid unnecessary movement /reversal of vehicles/ tippers/ pay loaders.

iii) Safe distance shall be maintained:

Between loading machine and the dumper stationed for loading.

Between two tippers / dumpers on movement.

Agent/Manager/ Asst. manager/ SO

Regular

11) Parking Instructions have been issued to all concerned for proper parking of the vehicles.

No vehicle shall be parked on slope/ gradient. If it is unavoidable, hand brakes shall be applied firmly, engine stopped, the vehicle kept in gear and stop- blocks against the wheels used and steering turned off-centre.

SO/ Engineer/operator As and when required.



To ensure safety of the contractual work force, following recommendations of various

safety conferences pertaining to contractual deployment have been considered while

preparing this Health & Safety Management Plan of Munsar Mine:

Provisions of 8th Safety Conference:

8th safety conference held in 1993 recommended the following for the safe guard of

contractor’s workers.

“5.6 Persons engaged in surface operations and, in particular, the contractors’ workers,

who incidentally are often inexperienced and least informed about job-safety matters, need

closer and more competent supervision. To minimize accidents due to surface operations, it

would be ensured that:

a) All persons engaged at any work within the mine premises through the contractors

have received relevant training and other job-related briefings and that the drivers of

vehicles belonged to contractors entering the mine premises have additionally been

explained about the salient provisions of “traffic rules”.

Each mining company should draw up appropriate training schedules and modalities in

this regard and implement the same.

In case of smaller mines, such arrangement may be made by association of mine

operators.

b) Each and every operation, including the operation carried out through contractors’

workers or outside agency, is placed under the charge of a competent supervisor, duly

appointed and authorized by the management, his jurisdiction being clearly

demarcated.


a) Suitable clauses (in consistence with risk of the work allotted) shall be included in

tender document (including NITs) stating how the risk arising to men and material

from the mining operation/operations to be done by the contractors shall be

managed.

b) Ensure that contractors are familiar with the relevant parts of the statutes, health and

safety management system and are provided with copies of such documents prior to

commencing work.

c) Ensure that contractor's arrangements for health & safety management are

consistent with those for the mine owner. All the rules, regulations and bye-laws as

applicable to the mine owner are also applicable to the contractor. Details of the

contractors’ workmen should be maintained in the owner’s Form-B register. Whereas

D & E registers for contractors’ men may be maintained independently by the owner

and shall be kept in the mine office of the manager.

d) Ensure that contracts should preferably of longer period (3 years), so that there is

adequate scope for management of safety by the contractor.



e) Ensure that contractors provide the machinery operator and other staff with written

safe work procedures for the work to be carried out, stating clearly the risk involved

and how it is to be managed.

f) Monitor all activities of the contractors to ensure that contractors are complying with

all the requirements of statute and the system related to safety. If found non-

compliance of safety laws, directing the contractors to take action to comply with the

requirements and for non-compliance, the contractor may be suitably penalized.

Clause to this effect may be a part of the agreement between the employer and the

contractor.

g) Where a risk to health or safety of a person arises because of non-compliance,

directing the contractor to cease work until the non- compliance is corrected.


i) The recommendations made in the 10th conference on Safety in Mines regarding safety, health and welfare of contractor’s workers shall be complied within two years. Owner, Agent and Manager shall be responsible for ensuring compliance at the respective mines.

ii) There shall be provisions for modifications in Notice Inviting Tenders (NITs) to fulfill the requirement of statute/circulars issued by DGMS from time to time subsequent to the finalization of NITs also.

iii) The contractor shall not employ or terminate his worker without the knowledge of the mine management.

iv) Payment to contractor’s workers including leave with wages shall be made through bank only.

v) In case of non-routine type of work in the mine a Work-Permit system, outlining the precautions to be adopted, SOPs, supervision, persons responsible for the job etc., shall be adopted.

vi) Each company shall frame a safety, health and welfare policy for their contractor’s workers keeping in view the requirement of Mines Act and Rules & Regulations made there-under. The details of the policy shall be included in the tender document which will be a binding clause for the contractor.

vii) Each mining company shall extend all benefits including medical facilities and payment of wages, to contractor’s workers receiving injury whilst on duty. Owner, Agent and Manager shall be responsible for ensuring compliance at their respective mines.

viii) Medical facilities shall be extended to contractor workers. ix) Central Government should take steps against non-compliance of the

recommendations of the National Safety Conferences.

Provisions of Circular No. 01/2012 related to contractual workers:

i) Contractual Employees should be selected on the basis of their educational,

professional and Job-need based qualifications, which should be recorded in their

Job- Card and Employment Register;

ii) Initial Training and Skill Development Programme should be framed based on the

Skills required which should be imparted for specified period under constant

supervision and monitoring by specialists;



iii) After completion of Initial training & Skill Development exercise, such employees

should be put on-job training under skilled employees with supervision of competent

persons;

iv) Normal or Regular jobs to contractual employees should be given only after

undergoing above stages of training & practices;

v) Extended hours of work, exposure to risky and hazardous places and operations and

deployment on skilled jobs should not be allowed for contractual employees;

vi) Initial and Periodical Medical Examinations including occupational safety and health

surveillance of all contractual employees shall be conducted by an expert agency

once in at least three years or at lesser interval.

Frequency of meetings to discuss the activities of Health & Safety Management Plan with

the role and objectives of such periodic meetings:

Dates of annual meetings and agenda:

1) Dates shall be fixed for meetings that will be attended by Agent, Manager, Assistant

Managers, Safety Officer and Head of departments of Mechanical, Electrical, Civil &

Project work, Medical, Personnel, Environmental and Survey.

Agenda for this meeting shall be:

a) Define Company’s safety, Health and Environment policy pertaining to Munsar

Mine;

b) A plan to implement the policy;

c) How the mine intends to develop capabilities to achieve the policy;

d) Principal hazard management plans;

e) Review of various Standard Operating Procedures/Codes of Practice;

2) Dates of annual meetings shall be fixed that will also be attended by Workmen

Inspector, Trade union Leaders, Safety committee members, senior foremen and Agent,

Manager, Assistant Manager, Safety Officer and Head of departments of Mechanical,

Electrical, Civil, Project work, Medical, Personnel, Environmental and Survey.

Agenda for this meeting shall be:

i) To measure, monitor and evaluate performance of the Health & Safety Management

Plan and matters that do not conform with the Health & Safety Management Plan;

ii) To review and continually improve the Health & Safety Management Plan;

iii) To review the Health & Safety Management Plan if significant changes occur;

iv) Details of involvement of Munsar mine workers (Both departmental and contractual)

in their development and application.

3) Dates of quarterly meetings to review/ new hazard identification shall also be fixed. All

the members mentioned in (2) shall attend this meeting.

4) Dates of monthly safety committee meetings shall also be fixed to review the activities

completed against planned; training achievements, work procedures etc. and accident

statistics and investigation. The committee shall also take appropriate decisions.

**********



Chapter - IV

Recommendations Following is the summary of recommendations given in the chapter on Safety

Management Plan and different tables which need to be considered by the Munsar mine

management for ensuring safety of the mine:

System management:

Health & Safety Policy framed by the management need to be reviewed and

circulated/displayed in mines in both English & Hindi to create awareness.

Its implementation should be reviewed by Board of Directors & Tripartite body at

intervals not exceeding 6 months.

The assigned duties, responsibilities to be handed over to the personnel concerned in

pocket book form in Hindi & English.

Analysis of accidents/ near miss to be widely circulated amongst all concerned, and

discussed in senior officers’ meeting.

Employees should be made aware of management’s role (Duty of care) vis-à-vis

employee’s role.

Emergency evacuation exercise (mock rehearsal) to be done regularly and record to be

maintained.

Formulate structured training programme for work persons, staff and management for

developing awareness and increasing effectiveness of emergency response.

Recommendations 2.1 (a to g) & 2.2 (a to i) of 10th Conference on safety in Mines

related to contractors’ workers should be implemented.

Exemption should be obtained from DGMS for utilising the services of WCL Rescue

station/MOIL Rescue Room Balaghat or it should be ensured that all the equipment as

mentioned in Schedule III {Rule 11(3)} of the Mines Rescue Rules, 1985 are maintained

at the mine.

Operational safety:

I) Strata Control:

Rock bolting is done as a system of support of development headings at Munsar

mine. The efficacy of the bolting system needs to be closely monitored as per

provisions of DGMS Cir, 11 of 2009 and Cir. No. 3 of 2010.

Physical examination: Test of roof bolts is conducted at the mine but Tensile Test

of the Roof Bolt Assembly should also be conducted for every batch of Roof Bolts &

its accessories received at their end before use. Proper records should be kept in a

bound paged book.

Length of the Roof Bolt shall not be more than the designed length + 5mm.

Diameter of the Roof Bolt shall not be more than the designed diameter + 4% by

mass as specified under IS 1786 – 2008 or as per the standard given in BS 7861

(Part-1) 2008.



Straightness: The roof Bolt shall be straight without any joint, welding, deviation

or deflection. However if the deflection or deviation cannot be avoided due to

practical reasons, it shall not be more than + 0.1 % per meter length of the bolt.

The Rib of the Roof Bolt shall be as per design with an objective to maximize the

surface area without reducing the core diameter of the roof bolt and having

maximum grip with the grout. However the height of the rib shall be kept within

the standard prescribed in IS 1786 – 2008 or BS 7861 (Part 1) 1996 or latest

revision thereof.

Steel for the Roof Bolt: The Yield Stress, Tensile Strength and % elongation steel

Grade shall be maintained as per the IS 1786 and IS 13920.

However the minimum load bearing capacity (Anchorage Load) of the roof bolt

shall be 160 kN.

The Roof Bolt Assembly shall be subjected to Tensile Test and should not fail up

to 160 kN load.

The Roof Bolts and its components or parts shall be subjected to Accelerated

Weathering Test in mine water condition for 20 days. No deterioration should

occur on the Assembly.

In order to check the composition and required parameters during manufacture, it

shall be required that the random sampling be done @ of 2 roof bolts per 1000

pieces of roof bolts and its accessories manufactured in a batch which shall be

subjected to the required set of tests as prescribed above and the data shall be

kept recorded in a bound paged book kept for the purpose which shall be signed

by the persons carrying out the test and shall be countersigned by the quality

control officer posted at the manufacturing unit(s).

In case the Roof Bolts or any of its accessories fail to pass the required tests, that

batch or lot of the manufacture shall not be used in the mine and intimation

thereof shall be sent to the manufacturer. A record in this regard shall be

maintained at the mine/company.

Since the roof bolts are being manufactured at the mine site, implementation of the

recommendations of the above circulars (DGMS Cir, 11 of 2009 and Cir. No. 3 of

2010) should be ensured.

The bearing plates used along with the rock bolts should be at least 8 mm thick

(reference DGMS Tech. Cir.(Approval) no. 11 of 2009 and Cir. 3 of 2010).

Written instructions regarding correct method of full column grouting of the bolts

need to be given to the support personnel. SOP may accordingly be modified.

At least the following apparatus and equipment for testing the efficacy of bolting

system shall be maintained at MOIL, Munsar Mine (refer DGMS Cir. 2 of 2009):-



Sr. No. Name of Apparatus/Equipment

Quantity Capacity

1 Viscometer One 10,00,000 cps 2 Anchorage Testing Machine One 50 Tonnes 3 Universal Compressive testing

machine One 50 Tonnes

4 pH meter One 0-14

II) Use of Machinery:

Codes of practice for maintenance of HEMM should be framed in Hindi and strictly

followed.

The codes of practice should be periodically reviewed and modified if needed to

ensure compliance of relevant circulars issued by DGMS from time to time.

To prevent unauthorised driving, the ignition key and/or cabin key shall always

remain with the driver/operator or with specifically designated/authorised

competent persons.

Only competent/trained operators shall be deployed to operate the machinery. Their

competency should be evaluated by a Board constituted by the company.

Operators shall not take out the machine for work unless he is satisfied that the

vehicle is mechanically sound and in efficient working order. He shall report any

defect observed, immediately to the manager, engineer or other competent person.

Safety posters shall be displayed at conspicuous places in the mine.

Jist of the SOP should be constantly displayed at every relevant place including the

haul roads, spoil/ ore heaps, material yards etc.

III) Explosives and Blasting:

To avoid pilferage, transit slip system for issue and use of explosive should be

continued.

Blasting card system should be followed meticulously.

All the approaches to the place of blasting should be fenced before blasting.

Written instructions regarding examining and securing the roof & sides within the

zone of influence (to be fixed by the mine manager) before permitting workers to

enter the area of blasting should be issued to the blaster and supervisory staff.

Separate Code of Practice should be prepared and copies issued from time to time

to concerned persons in the event of any two working faces approaching within

10 m.

IV) Shortage of skilled persons / deployment of unskilled persons:

Contractual employees should be selected on the basis of their educational,

professional and job-need based qualifications, which should be recorded in their job-

Card and employment register (refer DGMS Cir. 01 of 2012).

While doing manpower planning margin must be kept for expected absenteeism.



In addition to the training at the mine, efforts should be put to train the workers by

external competent agencies.

Simulator Training for all the HEMM operators may be arranged as recommended vide

DGMS Cir. 4/2011.

A system should be developed for employees to be examined against aptitude and

knowledge required for the job.

Contractor shall be instructed not to employ or terminate his workers without the

knowledge of the mine management (refer 11th safety Conference recommendations).

V) Transportation of ROM from underground:

Tub re-railers should be provided and kept at suitable places.

SOP on manual tub pushing should be framed in Hindi and displayed at prominent places.

Hand clamps may be provided to the tubs for holding and pushing the tubs from and in to the cage whenever the tub hoisting from vertical shaft.

Posters should be displayed at prominent places to create safety awareness.

Adequate lighting should be provided at all places where persons work or travel including haulage road, ore passes etc.

Drainage along the track should be clear of obstruction. Accumulation of water on track should be avoided.

VI) Safety Awareness:

A scheme may be incorporated wherein safe worker of the month and Gem of the

month will be chosen from amongst the safe employees and his photo will be

displayed on the specified board.

Safety suggestion of the month can also be invited; ensuring participation of larger

group including contractual employees and the best suggestion may be suitably

rewarded.

“Safety is my responsibility” Card should also be issued to all the contractual

employees in Hindi language containing 10 very important questions and no work

should be started by any worker without asking these 10 questions. Whenever

answer to any one of the questions is ‘No’, the worker should be urged to take the

matter to his supervisor for initiating corrective measures. (Refer Cir. 04 of 2013).

VII) Environmental issues:

Fugitive dust emission should be controlled from all the sources regularly by water

spraying arrangements on haulage roads, loading & unloading points and at transfer

points deploying adequate nos. of water tankers & permanent fixed sprinklers.

Illumination Survey should be conducted at regular interval and needful should be

done to rectify the defects if any to ensure good illumination.

Measurement of noise level at workplace should be conducted regularly, to take

appropriate action for control of noise level below 85 dB(A) in the work environment



and wherever the noise level exceeds the permissible level ear muffs should be made

mandatory.

Regular monitoring of water samples should be continued. Water Potability test

should be carried out regularly.

Siltation Pond/Check dams should be constructed to arrest flow of surface run-off

to outside nalla.

Ore laden trucks moving outside mine premises should be covered with tarpaulin. Zero

overloading should be ensured.

VIII) Occupational health:

Initial and periodic medical examinations (IME/PME) as per the recommendations of

10th safety conference should be done and computerised record should be

maintained.

The PME of group of workers deployed in areas prone to generate airborne dust

should be conducted at an interval of 6 months as suggested by DGMS Cir.1/2011.

Initial and periodic medical examinations including occupational safety and health

surveillance of all contractual employees shall be conducted by an expert agency once

in at least three years or at lesser interval (refer DGMS Cir. 01/2012).

IX) Surveying:

All plans should be linked to National Grid and periodically updated.

X) Training facilities;

Simulator Training for all the HEMM operators as recommended vide DGMS Cir.

4/2011 may be arranged.

A Board should be constituted to evaluate the competence of trainees especially all

the HEMM operators and they shall undergo regular checks to test their

driving/operating skill, knowledge at least once in every 5 years.

XI) Fires:

Code of practice for dealing with fires at different locations, machineries, vehicles etc. should be formulated and a proper fire-fighting organisation should be formed and trained at the mine.

‘Automatic fire detection and suppression system (AFDSS)’ should be fitted in all diesel equipment.

All high pressure hydraulic hoses should be replaced at the prescribed interval or earlier if there is any sign of deterioration.

XII) Supervision:

In addition to the statutory training and in-company training, supervisors should also

be exposed to out-company training programs.

XIII) Inundation:

Danger due to inundation is apprehended only in the event of heavy rainfall and

failure of underground pumps.



Pumps should be maintained regularly and especially before monsoon so as to avoid

any situation of inundation due to failure of pumps.

XIV) Electrical Safety:

Earthing of lightning arresters provided on receiving/sending ends of 11KV OH lines

should be insulated (Should not pass through any iron or steel pipe and should be

taken as directly as possible from the lightning arrestor to a separate Earth

Electrode) CEAR Reg. 74/2.

XV) Manual sorting, sizing & loading of ore:

Mechanization by installing crushing & screening plant may be introduced to

enhance safety & security of persons engaged in manual sorting, sizing & loading of

ore.

Kratin Solutions Pvt. Ltd has conducted hazard Identification and assessment of risk at

Munsar Mine of MOIL Ltd. on the basis of which Health & Safety management Plan has been

prepared for improving the safety of the mine and the workers employed therein.

It is worth mentioning here that Risk Assessment & Preparation of Health & Safety

Management Plan is not a one-time job. It should be properly implemented, monitored,

reviewed and revised periodically.

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Annexure



Permission granted under Reg. 107(3) MMR 1961 for carrying out stoping operations (Annexure-I-1)









The Environment Clearance (EC) for Munsar mine has been obtained (MoEF), Govt. of India vide letter no. J-11015/413/2007-IA.II(M) dated 26.12.2007, for a capacity of4166 TPM involving a total lease area of 149.06 ha (Annexure I-2).













Consent to Operate (CTO) was obtained vide letter dated 15.01.2013 (Annexure I-3)











4 nos. ambient air quality monitoring stations have been established at Munsar Mine. Quarterly air monitoring at these locations is being done by external agency M/s Anacon Laboratories, Nagpur (Annexure I-4)







The water quality parameters tested are – pH, Dissolved Oxygen, COD, BOD, Suspended solids, Oil & Grease, manganese. (Annexure I -5).



Noise monitoring is done at 4 points viz. UG pit, haul road, jack hammer drill & Ventilation Fan on quarterly basis by an external agency M/s Anacon Laboratories, Nagpur (Annexure I-6).

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