6th ASIAN MINING CONGRESS

23 – 26 February 2016, Kolkata, India

The Mining Geological and Metallurgical Institute of India (MGMI)

SAFETY MANAGEMENT SYSTEM FOR A LARGE

METALLIFEROUS OPENCAST MINE & SAFE PRACTICES
SK Mukhopadhyay*

ABSTRACT

Unlike the major industries, mining and steel industries have potential risk of accidents. A
major emergency in any Mine is also one, which has the potential to cause multiple serious
bodily injury or loss of life. It is now widely accepted world over that the concept of Risk
Management through Risk Assessment contribute greatly towards minimizing the risks and
accidents. “Safety Management System”- Strategies for Implementation and Path Forward, is
one of the valuable recommendations of 10th National Conference on Safety in Mines. Subsequently,
Directorate General of Mines Safety, Dhanbad, vide their DGMS (Tech.) (S&T) Circular No.13
of 2002(“Safety Management System”-a DGMS guideline for implementation thereof), DGMS
(Tech) (SOMA) Circular No.1 of 2008(a formal “Safety Management System”- Plan &
implementation thereof), DGMS (Tech) (S&T) Circular No.02 of 2011(preparation of ‘Risk
Management Plans’ and implementation thereof), and DGMS (Tech) Circular (MAMID) / 01 of
10th March, 2014, requested the Owner Agent and Manager of all Mines in India to undertake a
formal Safety Management System and implementation thereof, aimed at reducing the likelihood
and impact of mishaps of all kinds in Indian Mines. Keeping this in view, an attempt is being
made to focus on awareness of Safety Management System among Mining Industry.

1.0 INTRODUCTION The basic purpose of the “Safety Management

Time is now ripe to introduce initiatives and stress
upon areas of High Risk in order to bring them down to
acceptable levels. This can be achieved by introducing
the concept of Risk Assessments and Risk Management
Plan.
“Risk Assessment” studies are to be conducted on
regular basis for the effective implementation of “Safety
Management System” in all mines with the main aim to
reduce any High risks/ Moderate risks to Low risks, for
safe operation of different equipment and activities.
System” is to create a mechanism involving all concerned
at every level by which dangerous events and accidents
may be prevented.
• Safety to be monitored at the highest level of
Management.
• There should be an impetus inculcating Safety
awareness and adoption of an advanced Safety
Management System in the organization.

* JGM (Internal Safety Organisation), NMDC Limited, Lalapur Silica Sand Mines, Allahabad
436 Safety Management System for a Large Metalliferous Opencast Mine & Safe practices

CMFRI, NIMH, etc..

• All the employees working in mines are to be provided

with Personal Protective Equipment.

• Good housekeeping has to be maintained at all Mines.

• Training centers in all mines.

• They are to be equipped with infrastructure as required

under Mines Vocational Training Rules. These centers
would cater to the needs of basic training, refresher
training and training for skilled workers including
contractual workmen and also for those injured on
duty.

• Various on-the-job training programme are to be

• In each mining project, four number of workmen
conducted for all category of workmen including
inspectors are to be nominated/appointed, 2 for mining
contractual workmen.
operations, 1 each for mechanical and electrical
installations as per statutory requirements. • Training through e-Learning and Simulator should also
be started.
• Four workmen inspectors should be inspecting
different working areas twice in a week giving their • OHS Activities: Occupational Health Services are to
findings to the management. be provided with adequate trained manpower and
infrastructure and functioning in full-fledged manner
• Safety Committees have to be constituted in every
at all mines.
operating Mines.
• Headed by qualified Doctors trained in OHS at Central
• Safety Meetings are to be held every month
Labour Institute, Mumbai.
discussing the safety matters and corrective actions
related to working conditions. • Periodical Medical examinations under statute are
to be carried out in all mines with a planned
• Details of the accidents are to be discussed and
programme. All the results are to be computerized
analyzed in the Safety committee meetings.
and individual files are to be maintained.
• Dust suppression systems should be provided at
different locations in mines / plant.

• Regular water sprinkling.

• Mist spray at OCSL Plant.

• Illumination survey and Plan in mines and plant.

• High noise areas are to be demarcated with sign

boards with Noise levels.

• Noise mapping has to be commenced by Govt.

authorized body like M/s CMFRI, NIMH, etc..

• Suitable ear plugs / ear muffs are to be provided to

employees entering into these areas.

• Vibration studies are to be conducted in by M/s

SK Mukhopadhyay
Safety Management System
Safety Management System for Mines, has to be
prepared in line with -
• DGMS (Tech) (S&T) Circular No.13 of 2002
(A Safety Management System”- a DGMS guideline
for implementation thereof).
• DGMS (Tech.) (SOMA) Circular No. 1 of 2008
(A formal “Safety Management System”- Plan &
implementation thereof).
• DGMS (Tech) (S&T) Circular No.02 of 2011
(Mines are requested to undertake a formal risk
assessment process with the help of “Safety
Management System - A guideline for
implementation” was prepared and circulated as
DGMS (Tech) (S&T) Circular No. 13 of 2002. It should
be followed by preparation of ‘Risk Management
Plans’ and implementation thereof).
• DGMS (Tech) Circular (MAMID)/01, dated 10.03.14
2.0 SAFETY MANAGEMENT SYSTEM
• Safety Policy has to be prepared – follow up.
• Risk Assessments, Prioritization of Risks and Risk
Management Plan
• Disaster Management Plan - Implementation & follow
up: Mock Rehearsal
• Safety Management System – Preparation,
Implementation & Review.
Safety Policy:
The organization is committed for prevention and
control of occupational diseases, injuries and environmental
437
pollutions due to its activities, products and services. The
organization will achieve the same through its well defined
commitments and effective implementation of Safety
Management System.
The company will monitor its Safety performance on
regular basis to ensure the continual improvement of the
same.
We shall therefore endeavor to :
• Adopt safe, scientific and environment friendly
methods of mining and allied activities and
firmly committing ourselves for total compliance of
Mines Act, Mines Rules, Mines regulations etc. by
Directorate General of Mines Safety & other
requirements applicable to Safety.
• Maintain the machineries in safe and excellent
condition to ensure minimum impact of their operation
on Safety of employees and contractlabours.
• Promote Safety awareness among employees,
contract labours, local communities and interested
parties through active communication and training.
• To have emergency preparedness plan in place,
remain prepared through regular mock rehearsals &
practices and respond effectively for ensuring
Safety to all in every possible emergency situations.
• Management will review the suitability and
effectiveness of Safety objectives and targets through
Risk Assessment and its periodic Safety
Management review process.
The Policy shall be communicated to employees and
contract labours and will be made available to the
public, on request.
Safety Management System - elements:
• Safety Policy of the company.
• Roles and Responsibilities of all levels in the
organization
• Safety Committee and role
• Risk Assessment Plan - Method to identify and
control high risk
• Accident analysis with root causes
438 Safety Management System for a Large Metalliferous Opencast Mine & Safe practices

• Monitoring processes for all identified hazards with

or without residual risks

• Plan to ensure actions to control hazards .

• Disaster Management Plan to cope up with a hazard.

• Identification of trigger points and resultant actions.

• Safe Operating Procedures (SOPs) for different

equipment, and Operational Control Procedures
(OCPs) for specific activities.

• Review process

• As per this System, mine management would have

to identify all the hazards in Mine associated with
various mining activities.

• Risks associated with these hazards have to be

analysed.
• Prioritization of Risk has to be done considering
Probability, Exposure and Consequence of the Risks.
• Based on Prioritization Steps have to be taken to
bring all risks to the acceptable levels.
• For Safe and Systematic operations Work Instructions
(WIs) for different works have to be prepared.
• It is to ensure that all works / operations / activities
are carried out as per the procedures and are strictly
adhered to by one and all.

3.0 RISK SCORING 4.0 DISASTER

• Risk score = Likelihood x Consequence

• Risk score = Probability x Exposure x

Consequence

HEMM Equipment Fire

Disaster Management Plan

• Disaster Management occupies an important place
in any Industry.

• In the organization Disaster Management Plan has

• Safe Operating Procedures (SOP’s) and Safe
Maintenance Procedures (SMPs) for various
operations / activities have to be prepared in the
mines, in English, Hindi and local languages.
to be been prepared and to be got approved by the
respective District Collectorate. The plan focuses
mainly on Organization, functions, Roles &
Responsibilities.
• For all Mines – Implementation, Regular Mock
rehearsals & Periodic Review.
SK Mukhopadhyay
Disaster Plan Organization:
The following organization set up is to be established
at each mine for chain of command to deal with the disaster
at mine levels:
• Project Heads: Has to coordinate among all
functionaries .
• Mines Manager: Chief Coordinator
Duties of Mines Manager /Chief Coordinator:
On receipt of the information about the incident, Mines
Manager/Chief Coordinator shall forthwith rush to the spot
439
and assess the extent of the crisis. He shall execute the
overall rescue operation and take necessary steps for the
arrangements of medical aid to affected person, if any.
• Ensure that casualties are receiving adequate
attention.
• Liaise with Chief Officers of the Fire/Explosives etc.,
Police services, Directorate General of Mines Safety,
and District authorities.
• Make an arrangement for maintaining a emergency
log – book .
• Ensure rehabilitation of affected people after the
emergency.
• Head (Pers): He will be the co-ordinator for civil
authorities, CISF, Fire wing for fire-fighting operation,
safety, and emergency rescue operations, media and
communication with families of affected employees.
• Head (Matl)/Head (Maint. & services) : He will be
maintenance co-ordinator and arrange items if needed
for rescue in case of emergency.
• Chief Medical Officer: He will be medical service co-
ordinator.
• Commandant CISF / Security Incharge: He will co-
ordinate for extending all type of assistance in
connection with security / emergency coverage.
Emergency Control Room/Center:
Control Room for Emergency will be established in a
suitable location in Mine/plant premise with effective
communication arrangements, large scale maps of the area
and stand by vehicles for meeting emergency requirement.
HOD (Pers.)/HOD (Maint.&Ser.) coordinator, will take
charge of emergency control Room. He will also pass on
instruction to various emergency coordinators for their
action.
Control of the Information Media, viz. ‘press, radio
and television’ will be necessary. The HOD (Personnel)
will do ‘press’ briefing. The ‘press’ must be kept out of the
forward operational area and this can be effectively
achieved only if they are given regular official progress
reports, prepared and cleared for publication through the
Government Control Agencies.
440 Safety Management System for a Large Metalliferous Opencast Mine & Safe practices

Mock Rehearsals: TMS = Total manshifts worked in the Mine

Mock Rehearsals are to be conducted periodically
Other details of the Criteria for NSA have already
for assuring the preparedness and effectiveness of the
given in the prescribed form of application
Action Taken Plan, participation and response of concerned
In-charges/teams against the situation of Disaster. Let us all strive hard jointly, for achieving the National
Safety Award (NSA) year after year, by “Improving the
Safety standards of our Mines”.

‘Safety Pin’ points:

• I am committed to Safety

• I’ll not do work at mine without PPE

• I will follow SOP & Safe WI at Mine

• ’Preventive measure’ is better than

‘Disaster’
Tips of Safety Management System:

• Statutory Compliance
• The improvements in Safety & Health would be
achieved through strictly adhering to statutory laws. • (Safety Management) System

• Safety Management System is to be audited • People – Behavioural Safety (Management)

periodically by internal auditor. The same is to be
audited by external agency once in every year. • Safe Positive Attitude

Accident Analysis • Safety Culture

For National Safety Award
Criteria for National Safety Award 5.0 CONCLUSION
Scheme 1: Longest Accident Free Period (LAFP) The elements of Safety Management Planning can
be effectively applied to all Emergency Situations. The
Scheme 2(A): Lowest Injury Frequency Rate per
goal always is to keep a potential Emergency team work
lakh Manshifts (LIFRLM)
or the united effort which is essential for the effective crisis
• For any Mine, 3 consecutive years period is being management because of the wide variety of individuals,
considered (ending with the contest year) for organization skills and equipment which must be employed
calculation. in an Emergency. An efficient Safety Management Plan
can assist officers to cope up with the horrendous
1) LAFP = No. of manshifts worked during the
experience associated with major crisis by the way of
Longest Accident-Free Period.
planning, training and unity efforts. A properly trained
(50K+S) X 1,00,000
Emergency Management team that springs instantly into
2) IFRM = —————————————
TMS action, anticipates the crisis and retains the initiative
throughout, enhances the image of the organization and
IFRM = Injury Frequency Rate per lakh manshifts.
will certainly help to preserve its dignity.
K = Total No. of fatalities in Mining Statistical
Accidents in the Mine.
“Safety is every body’s business and it is not
one man’s job”.
S = Total No. of workers seriously injured in
Mining Statistical Accident in the Mine.