smart safety in urface mines · 2018. 3. 9. · indian mining industry –growth scenario 2.9 2.8...
TRANSCRIPT
Smart Safety in surface mines- technological advancements & scenario
CII Eastern Region Safety Symposium & Exposition
ITC Sonar, Kolkata
Debashish Jena
09th Sep’2016
Kolkata, India 1
Contents
� Indian Mining industry – growth scenario
� World scenario – Iron ore & Coal
� Indian Coal Production at a glance
2
� Safety perspective
� Smart Safety - Technological Interventions
� Tata Steel Smart Safety initiatives
Indian Mining Industry – growth scenario
2.9 2.8 2.7 2.7 2.6 2.6 2.8 2.72.4
2.12.4
3.4
0
0.5
1
1.5
2
2.5
3
3.5
4
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 (P) 2014-15 (P) 2018-19
(Proj.)
Share of Mining - % of GDP
- 6th July 2016
� India produces 88 minerals – 4 fuel-related
minerals, 10 metallic minerals, 50 non-metallic
minerals and 24 minor minerals.
� FDI up to 100% is allowed in exploration,
mining, minerals processing and metallurgy
under the automatic route for all non-fuel and
non-atomic minerals including diamonds and
precious stones. (FDI in coal mining is allowed for captive consumption only.)
� Uniform lease period of 50 years; no renewals;
auction at the end of lease period.
3
Mining Industry
5
Exports
213213213213 215215215215 218218218218207207207207
169169169169
136136136136151151151151
111111111111
155155155155
200200200200
311311311311
392392392392
104104104104 106106106106117117117117
98989898
62626262
18181818 151515150000
50
100
150
200
250
300
350
400
450
Total Iron Ore Production
Iron Ore Production trend - India In Mn T
Exports5555
0000
0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
(forecast)
2025
projections
@ 7% GDP
growth
2025
projections
@ 8% GDP
growth
� India ranks 5th in World Iron ore reserves (as on 01.04.2010 – Hematite – 20.57 Bn T,
Magnetite- 10.74 BnT)
� Crude steel capacity is poised to grow – envisaged capacity – 300 Mn T by Fy’26
� India’s per capita steel consumption is four times lower than the global average.
* Reserves includes remaining resources 6
* Source : IBM
532 533 540556
566612
1500
0100200300400500600700800900
1000110012001300140015001600
Total Coal Production
o 3rd largest producer of
thermal coal
o Coal Reserves : ~ 300 Bn T
o While production has
increased over the past few
decades, the pace of growth
has been insufficient to meet
demand
o More reliant on imports
In Mn TCoal Production at a glance - India
44444444 50505050 52525252 52525252 57575757
488488488488 483483483483 488488488488 505505505505 509509509509
532 533 540 556 566
0
100
200
300
400
500
600
700
2009-10 2010-11 2011-2012 2012-13 2013-2014
Coking Coal Non-Coking Coal Total Coal Production
02009-10 2010-11 2011-2012 2012-13 2013-2014 2014-15 2020 Projected
o More reliant on imports (thermal coal imports from 10 Mn T (2000)
to 142 Mn T(2013)
o India is projected to overtake
the United States as the
world’s second largest coal
consumer before 2020
* 2020 projections : CIL -1 Bn T Non-CIL- 0.5 Bn T
* Reserves includes remaining resources 7* Source : MoC
~90% from Surface mines
~10% from U/g mines
Environmental management
• Air quality
• Water quality
• Noise
• Land reclamation
Environmental Issues
• Slime storage for safe disposal and re-
use
• Dust suppression arrangements
• Plantation on dumps and in colony
Technical Issues
• Selecting best practices in mining
• Technical reclamation of internal
and external dump with proper
slope and benching
• Disposal of wastes/ rejects in case
of beneficiation plant Technical aspects
• Ensuring proper slopes of the benches
• Voids management
• Dismantling of infrastructure
• Disposal and utilisation of equipment's
Fencing and sealing/ closing of mine
entries
During operation After closure
Approach for ‘best in class’ mining
8
Safety & health issues
• Health monitoring – periodic
health check-up
• Risk and disaster management
Social issues
• Resettlement and rehabilitation
• Providing community facilities like
roads, drains, water supply,
electricity, school, hospital/
dispensary, etc.
Financial aspects
Financial provision for the above
issues is provided in the Project
Report itself.
Social aspects
• Manpower utilisation/ redeployment
• Impact on other stakeholders/ villagers
Final closure plan
Final closure plan shall be submitted one
year prior to the proposed closure of the
mine
Implementation protocol
Final closure plan shall be implemented by a
multi-disciplinary team under the sr leadership
of the concerned mining company
All these aspects leads to sustainable mining value chain
Indian Safety Scenario (Mining)
Indian Safety Scenario (Mining)
• Regardless of the job in the mining industry, a potential for dangeralways exists
• Mining has few constant factors and many variables
• Environment, conditions, and human factors all impact this risk
There is Risk in Everything We Do
Environment, conditions, and human factors all impact this risk
• Risks must be eliminated or mitigated by identifying, evaluating,and controlling the hazards as each task is performed
• Performing this process on a recurring basis creates system safetyand health
11
Associated Hazards & Risks
MANAGING HAZARDS
1
3
Top Management Commitment
Visible Management Commitment --- is the starting point and key to success
OrganizationOrganizationPolicyPolicy
Responsibility & Accountability
Responsibility & Accountability
Goals & Objectives
Goals & Objectives
StandardsStandards
MotivationMotivation
CommunicationCommunication
TrainingTrainingObservationsObservations
SupportiveSafety
Personnel
SupportiveSafety
Personnel
IncidentInvestigations
IncidentInvestigations
Visible ManagementCommitment
Visible ManagementCommitment
14
Safety Management System
15
How Do We Handle Hazards
16
TRADITIONAL WAY of SAFETY MANAGEMENT SYSTEM
1
7
TRADITIONAL WAY of SAFETY MANAGEMENT SYSTEM
Need to shift the focus from traditional way of looking
F
O
Lagging
Indicators
(Fatality, LTI,
First Aid,
Property
Damage, etc.)
O
C
U
SLeading
Indicators
(Near Miss,
Observations,
Trainings,
etc.)
18
Did we meet our TARGET – ZERO HARM
Point to Ponder19
Major Factors affecting Safety Management System
20
Human Factor in Safety Management System
21
Factors affecting Human Criteria
22
Single stop solution – SMART SAFETY
23
What is SMART SAFETY…
Smart Safety
IT Integration/
Digitisation/Internet
of things
Improved
Process/Autom
ation
24
Central Monitoring
Systems
Remote
Operations
Mines Size – Where do we stand ? ‘In million tonnes
290
9 mines
327 306 mines
197 mines
Fy’10 (218 mt)No.of operating
mines: 316captive -28
Non-captive- 282
Fy’14 (151 mt)
No.of
operating
mines: 298
15 mines290
2508 mines
17 4 mines
Note: Production from Fy’14/Fy’15
…. Primarily due to large size mines and high degree of mechanization
~47m3 ~400 tons ~10 m3 ~100 tons
mines: 298captive -29 Non-captive- 264
25
18 2012 fig.
In-pit crushing and conveying system‘to reduce carbon foot print and reduce traffic intensity ’
Paste iron ore tailings disposal‘to conserve water and safe storage for slime ’
Smart Safety - Technological interventions
Use of Drones
‘for quick surveying, stock pile inventories, monitoring geo-
technical issues etc.,
26
Remote Blasting‘less labour intensive and safe blasting practice’
Real time equipment data capturing – Fleet
management system, Tyre pressure and
Monitoring system‘to improve equipment productivity, to increase tyre life
and to reduce carbon foot print’
Smart Safety - Technological interventions
27
Autonomous Haul truck/ Trolley assisted haul truck
‘to eliminate human exposure and to reduce carbon foot
print’
Smart Safety - Technological interventions
Training Simulators‘to enhance training effectiveness before deployed d in mines ’
Blast fragmentation analysis‘to improve safety – from manual monitoring to
on line automated process
28
Pile management using 3D Scanner‘remote tracking of stock pile management’
Use of mobile applications for performance
tracking/planning purpose‘online real time data visibility and tracking’
Smart Safety - Technological interventions
Highwall mining‘mining the unmineable remotely with greater safety’
Stemming truck for back filling of blast holes‘eliminate human exposure by mechanisation’
29
Surface continuous miners‘eliminate drilling & blasting – cutting capability for
compressive strength up to~120 MPa’
Slope stability radar‘for continuous real time monitoring of steep slopes ’
Tata Steel – Smart Safety initiatives
30
#Digital #
#PLC based control with
advanced monitoring
equipments & PIMS#Mobile APP based
Daily Report
31
#Shift data logging via
mobile APP
#Central Complaint
Management System
#Yard Management (Pile
Mapping) using 3D Scanner
#Digital #Future Ready
#FMS
#Remote Monitoring of
32
#Remote Monitoring of
Operating Parameters & CCTVs
via Mobile APP
#Centralized Security
Control Center
#Centralized Information
Management System
CIMS
#Digital #33
#GPS Based Vehicle
Tracking System
#3D Laser Scanner for
Surveying
#XACT for Short
Term Scheduling
34
Alarm theory :
Driver fatigue alarm system reminds the driver that he/she is in a
dangerous state.
The EA-430 (Make: Lumeway) uses a PERCLOS algorithm to analyze the
driver’s fatigue level.
The state of the driver’s eyes is constantly analyzed. The human retina
reflects infra-red light in a manner that can be used to determine the
eye’s condition. This varies just prior to falling asleep. The EA-430
knows drivers are falling asleep before they close their eyes.
If the EA-430 determines the driver is in a dangerous state a sharp voice
will alert the driver.
Fatigue Monitoring in Dumpers
35
Vehicle tracking & Monitoring system
1. Speed Violation Report (Online)
2. Night Driving Report (Offline)
3. Continuous Driving (Offline)- This report provides
the details of the vehicles which are in continuous
driving mode more than a specified permitted time
period.
4. Alerts (Online)- All SOS gets recorded in this link
(like, Overseed/ Acceleration /Deacceleration/
Battery Disconnection/ GPS
disconnection/Polygonal geo-fencing, etc.)
5. 1sec data (Offline)- For analysing driving pattern of
36
5. 1sec data (Offline)- For analysing driving pattern of
the driver at the time of accident of the vehicle.
Available for 8 hrs. in any equipment.
6. Live Tracking (Online)- 24x7 live tracking module.
7. Google Map (Online):
O Vehicle Position
O Vehicle Point
O Vehicle Polyline- Path travelled by a selected
vehicle
8. Other Online Information:
· Vehicle at Maintenance
· Driver Mapping
· Trip upload, offload, trip details
Speed Violation Report
37
LIVE Monitoring – Mobile App
Coverage of all working areas through surveillance camera
Rapid Loading System
40
Log Observations – Anytime, Anywhere
Slope Stability Radar
www.IItbhu.ac.in
• Slope stability is a critical safety and production issue for coal mines. A common technique to determine slope stability isto monitor the small precursory movements, which occur prior to collapse. It is a state-of-the-art development formonitoring slope movement in open pit mines. It offers unprecedented sub-millimetre precision and broad area coverageof wall movements through rain, dust and smoke. The real-time display of the movement of mine walls has allowedcontinuous management of the risk of slope instability at a mine operations level. There are two key roles where minesare now using the slope stability radar:
1. Safety Critical Monitoring: The radar is used during mining production as a primary monitoring tool of a designated unstableslope.
2. Campaign Monitoring: The radar is moved around the mine in a repeatable manner to compare movements at each site overan extended time, and determine problematic areas. Campaign monitoring in this manner is often used in metalliferous minesuntil determination of developing failure is observed.
Safety Parameters & Document Management
Safety Excellence Management System4
4
Electronic Displays
Thanks
46
S S sSmart Safety in surface mines- technological advancements & scenario
Debashish Jena
09th Sep’2016
Kolkata, India