Safety and Health Performance in Indian Coal Mining

By

Shri R.B. ChakrabortyDy.Director General of Mines Safety

DGMS, Dhanbad – 826 001

Growth in Coal SectorIn the last two decades, coal mining has witnessed aphenomenal growth in production from 75 million Te in 1971-72 to 429 million Te in 2005-06 and has touched about 490million Te (including lignite) during 2007-08.

Coal Vision 2025 estimates the demand of coal for future upto2024-25 for the different sectors based on the forecast madeby TERI considering the coal demand and the change in theGDP. The adopted approach indicates that the overall growthin coal demand is expected to be 5.62% with 8% GDP growthscenario and 5.04% with 7% GDP growth. Sector-wise coaldemand as assessed with the above approach for the twoscenarios are given.

Sector-wise demand for coal (in Million tones)

Consumer Terminal year of five yearly plan

Xth Plan

2006-07

2011-12 2016-17 2021-22 2024-25

7% 8% 7% 8% 7% 8% 7% 8%

Power utilities

317 412.69 427.16 517.31 552.56 635.46 698.53 718.94 804.03

Power Captives

28.26 43.26 44.33 59.89 62.96 83.5 90.04 101.93 111.6

Steel 42.7 53.13 54.24 66.57 69.49 83.87 89.52 96.54 104.50

Cement 25.4 38.4 39.39 58.18 61.06 88.16 94.12 113.13 123.47

Bricks and others

59.82 63.52 64.51 79.57 82.11 100.72 105.62 116.54 123.41

Total 473.18 611.45 629.63 781.52 828.16 991.7 1078.54 1147.54 1267.01

Production Plan From Indigenous Sources

Considering the high growth in coal demand scenario, eitheras per the assessment of Coal Vision 2025, or as per theestimates of the Administrative Ministries of coal consumingsectors, there is a need to increase the availability of coalfrom the indigenous sources. With this in mind coalproduction programme in different “Plan Periods” has beenworked out. Coal demand (with 8% growth of GDP), asenvisioned in the Coal Vision 2025 document, is expected torise to 1267 million tonnes per annum by 2024-25.

Breakup of Production from underground mining and opencast mining in projection of coal production.

Company X th paln(06-07)

XI th Plan(11-12)

XII th Plan(16-17)

XIII th Plan(21-22)

XIV th Plan(26 – 27)

OC UG Total OC UG Total OC UG Total OC UG Total OC UG Total

CIL 321.8 51.2 373 448.5 59.5 508 568 80 648 655 100 755 715 124 839

SCCL* 25.8 11.9 37.7 28.7 12.3 41 31.5 13.5 45 32.9 14.1 47 32.9 14.1 47

Others **

Captive

TISCO /

IISCO

19 2.0 21 39.6 4.4 44 67.5 7.5 75 112.5 12.5 125 157.5 17.5 175

Total 366.6 65.1 431.7 516.8 76.2 593 667.0 101 768 800.4 126.6 927 905.4 155.6 1061

* SCCL figure of UG & OC production has been calculated on the basis of ratio of production from UC (30%) & OC (70%) in 2006-07.

** Underground production has been taken 10% of the total production.

Share of Coal Production fromUnderground and Opencast

Year Underground Opencast TotalProduction

(Mt)% Share Production

(Mt)% Share

1951 30.19 86.32 4.19 13.68 34.38

1971 58.55 77.41 17.09 22.59 75.64

1991 70.73 29.75 167.06 70.25 237.79

2001 64.13 18.78 277.37 81.22 341.50

2006 63.00 14.93 359.00 85.07 422.00

2007 63.01 12.50 359.99 87.50 423.00

Projected Share of Coal Production from Underground and Opencast

Terminal year of five yearly Plan

Underground Opencast Total

Production(Mt)

% Share Production (Mt)

% Share

XI (11 - 12) 76.2 12.85 516.8 87.15 593

XII (16 - 17) 101 13.07 667 86.85 768

XIII (21 - 22) 126.6 13.65 800.4 86.35 927

XIV (26 – 27) 155.6 14.69 905.4 85.33 1061

Technology for Coal Production

Opencast Mining

Underground Mining

Phasing Out of manual loading by mechanized loading. Use of mass production technology like continuous miners – shuttle car. Increase in powered support longwall in dipper horizon. Introduction of shortwall mining with powered support to extract

already developed pillars. Use of road headers for faster development of headings. Replacement of conventional bolting by mechanized roof bolting

machine.

Occupational Safety and Health in Mines An Overview

Hazardous Profession

Status of Safety in Indian Mines

Accident Experience

Trend in Fatal Accidents and Fatality rates per 1000 person employedand per million tones coal produced

Year No. of Fatal Acc. No. Killed D. Rate /

1000 Pers.D. RateMill. Te.

1951 278 319 0.91 9.3

1961 222 268 0.65 4.81

1971 199 231 0.60 3.05

1981 165 184 0.36 1.45

1991 138 143 0.26 0.60

2000 117 144 0.31 0.43

2001 105 141 0.32 0.41

2002 81 97 0.23 0.27

2003 83 113 0.27 0.30

2004 87 96 0.24 0.26

2005 96 117 0.29 0.29

2006 79 138 0.36 0.34

2007 77 79 0.20 0.19

2008 87 100 0.25 0.24

Cause wise fatal accident in coal mines in belowground opencast and aboveground during 1995 - 2005

Cause B/G O/C A/G Overall Fall of roof 306 0 0 306Fall of side 97 9 0 106Other ground movement 4 4 0 8Transportation machinery 16 0 0 16Rope haulage 116 0 4 120Wheeled trackless transport 0 146 64 210Other transportation machinery 18 5 22 45Machinery other than transportation machinery 17 54 25 96Explosives 30 4 1 35Electricity 7 14 21 42Gas, dust and other combustible material 9 10 5 24Fall of Person 37 12 25 74Fall of object 10 8 6 24Other falls 1 2 0 3Irruption of water 11 0 0 11Flying pieces 1 0 1 2Miscellaneous 6 7 4 17Total 686 275 178 1139

Predominant cause of accident in underground mines:

1. Fall of roof - 44.60%

2. Fall of side - 14.14%

3. Rope haulage - 16.91%

4. Other transportation machinery - 2.62%

5. Machinery other than transportation machinery - 2.48%

6. Explosive - 4.37%

7. Fall of persons - 5.40%

Predominant cause of accident in opencast mines:

1. Wheeled trackless transport - 53.7 %

2. Machinery other than transportation machinery - 19.42 %

3. Electricity - 3.7 %

4. Fall of persons - 3.0 %

Predominant cause of accident in aboveground :

1. Wheeled trackless transport - 28.0 %

2. Other transport machinery - 16.10 %

3. Machinery other than transportation machinery - 15.25 %

4. Electricity - 15.25 %

5. Fall of persons - 12.71 %

Roof fall14%

Fall of objects4%

Side fall8%

Explosives1%

Fall of persons4%

Rope haulage3%

Other m/c16%

Other causes19%

Dumper/Trucks31%

COAL MINES

CAUSEWISE ANALYSIS OF FATAL ACCIDENTS, 2008

0

20

40

60

80

100

2004 2005 2006 2007 2008Coal Metal Oil

No.

TREND IN FATAL ACCIDENTS IN MINES

Note: 2008 figures are provisional

Total no. of fatal accidents,

2004- 2008

COAL: 428

METAL: 275

OIL: 17

TOTAL: 720

0

200

400

600

800

1000

1200

2004 2005 2006 2007 2008Coal Metal Oil

No.

Note: 2008 figures are provisional

Total no. of serious accidents,

2004-2008

COAL: 4460

METAL: 424

OIL: 103

TOTAL: 4987

TREND IN SERIOUS ACCIDENTS IN MINES

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1901-10 1911-20 1921-30 1931-40 1941-50 1951-60 1961-70 1971-80 1981-90 1991-00 2001-08

Decade

Fata

lity

Rat

e/ 1

000

pers

ons

empl

oyed

Coal Mines Non-Coal Mines

TREND IN FATALITY RATES/ 1000 PERSONS EMPLOYED: TEN YEARLY AVERAGE

0

1

2

3

4

5

6

7

8

9

10

1951

1961

1971

1981

1991

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

TREND IN DEATH RATE PER MILLION TONNES OUTPUT: COAL MINES

1951 - 2008

OIL4%

OTHERS13%

STONE4%

LIMESTONE7%

MANG1%

IRON11%

GALENA& SPH1%

COAL57%

Analysis of major accident and disaster from 1901 to 2007

Number of (Persons killed)

Year Explosion Inundation Fall of roof Side fall Fire / Gas

1901-2007 37 (1258) 33 (829) 136 (840) 23 (147) 8 (125)

Suggested Measures to prevent Accident

Accident in Underground Mines:

Ground Movement :

Belowground accident contributes 60% of the total accidents in coal mines. In belowground mines roof fall contributes 44.6% accidents. Fall of roof and fall side together contributes about 60% accidents. From analysis of disaster it may be seen that fall of roof though it is not

generally considered as a contributory of major accident / disaster yet it haskilled 840 persons in 136 major accident / disaster which is more than thepersons killed due to inundation. If we add other accidents due to (1/2/3

fatalities) roof / side fall it will become single major contributing causeof underground accidents.

a) In every coal mining company, STRATA CONTROL CELL shall be established at corporate and arealevels within a period of one year, to assist mine managers, for formulation of Systematic SupportRules, monitoring strata control measures in a scientific way to ensure efficacy of support system andfor procurement / supply of quality supporting materials. Such cell shall be manned by adequatenumber of technical personnel headed by a senior official not below the rank of General Manager atCorporate level and Dy. General Manager at Area level.

(a) Roof bolting shall be used as a primary means of support for freshly exposed roof in development aswell as depillaring districts. For the roof category “Poor”, having value of RMR of 40 or less, or wherethere is excessive seepage of water from the roof strata, roof bolts exclusively with resin capsulesshall be used to ensure adequate & immediate reinforcement of the strata.

(a) Due emphasis shall be given to support the sides of galleries while framing Systematic Support Rules.

(a) Suitable steps shall be taken by the mining companies to inculcate a culture of “no work at face”other than supporting work, till the roof is supported by roof bolts up to at least 0.6 meter from theface.

(a) To ensure proper drilling for roof bolting in all types of roof strata, suitable fit-for use roof boltingmachines shall be introduced in all mines within a period of one year. Such machines shall be capableof being operated from a distance or be provided with suitable canopy to protect the supportingpersonnel during drilling or bolting operations.

(a) Risk assessment exercise shall be carried out in the mines for assessing the risk from the hazards ofroof & side falls and identifying the control mechanism with specific responsibility for implementation.This exercise shall be reviewed at regular intervals not exceeding a year.

(a) Each company shall take steps to impart structured training to officers, supervisors and supportpersonnel on roof bolting.

10th Conference on Safety in Mines elaborate deliberations

Face Mechanization Keeping in view the objective of phasing out manual loading, all coal companies shall identify

appropriate technology suitable for the prevailing geo-mining conditions and introduce the same insuch a manner so as to phase out manual loading operations completely within a period of five yearsin coal seams with gradient of 1 in 5 or less, and within a period of seven years in coal seams withgradient steeper than 1 in 5.

While formulating the strategies for face mechanization in underground workings, it shall be ensuredthat back up facilities like coal evacuation, support system, ventilation arrangements etc. arecompatible with face mechanization.

The scheme of face mechanization shall be based on proper scientific investigation. The schemeshall also include arrangements for monitoring strata behavior and environmental conditions.

Possibility of deployment of multi-skilled miners in the face shall be explored to reduce the exposureat hazardous area without affecting employment.

Suitable training for efficient & safe operation of machinery shall be imparted to all concerned.

While planning for face mechanization, due considerations shall be given for long term sustainabilityof the technology.

A policy document shall be framed by each coal mining company within a period of six months foraddressing the implementation issues. It shall also be ensured that all safety precautions areincorporated in the policy document.

Suggested Measures to prevent Accident

Accident in Opencast mines

Opencast accident contributes 24% of the total accidents in coal mines.

In opencast mines wheeled trackless transport contributes 54% accidents andmachinery other than transportation machinery contributes 19%

accidents. Together they cause 73% of accidents in opencast mines.

It is necessary to control the movement of machineries by introducing andimplementing traffic rules, standard operating procedures, maintaining

proper haul roads, lighting, dust free environment, designing suitable cabins andmaintaining the machinery in safe working order.

Suggested Measures to prevent Accident

Accident in aboveground

Aboveground accident contributes 16% of the total accidents.

In aboveground wheeled trackless transport contributes 28% accidents. Causes like other transport machinery, machinery other than transportation machinery, electricity contribute 16%, 15% and 15% accidents respectively.

About 60% accidents are caused by all types of machineries in above ground.

Suggested Measures to prevent Accident

Safety in Contractor’s Workers

Employer’s responsibilities Contractor’s responsibilities Employee’s responsibilities

Statutory manpower

R&D input for improving safety

Training

Better safety:Some critical issues

Insufficient basic educationInadequate trainingEnforcement ProblemsLack of safety cultureProblems with concept of self-regulationInadequate workers’ rightsLess tripartite cooperation or social dialogue

WELFARE ACTIVITIES UNDERTAKEN UNDER THE AEGIS OF DGMS

FACILITIES OFo CANTEEN CRÈCHE, o DRINKING WATER, o REST SHELTERS, o FIRST AID ROOMS, o FIRST AID STATIONS, o LAVATORIES, o INITIAL MEDICAL AND o PERIODICAL MEDICAL EXAMINATION

AS PER STATUTE ARE PROVIDED IN COAL ANDNON-COAL MINES IN THE COUNTRY.

AWARENESS GENERATION PROGRAMME

SAFETY COMMITTEES IN MINES, WORKMEN INSPECTORS, SAFETY SEMINARS,

CONFERENCES. LECTURES TO WORK PERSONS, SUPERVISORY STAFF AND OFFICERS IN THE

MINES ARE REGULARLY DELIVERED. MANAGEMENTS UNDERTAKE TOPICAL SAFETY DRIVES IN THE MINES PERIODICALLY UNDER

DGMS GUIDANCE.

Conclusion

The scenario of Indian coal mining is changing veryfast with the increasing demand for coal to meet thecountries energy security. Technology for production ofcoal, management and geotechnical environment willsee great change in near future. The expectation ofthe society is also increasing day by day and theaccident is not accepted any more. It is high time toassess the future requirements in terms of safety ofwork persons and draw the road map to make furtherimprovement in terms of reduction of accident andoccupational safety and health in totality.

Thank you