Safety and Disaster in Mining Education What is being taught? Mine Safety and Legislation: A compulsory subject of Mining Engineering Progrmme General provisions of mines and mineral regulation and development act, Mineral concession rules, Mines act, regulations and rules, bye-laws and circulars, Mines vocational training rules, Land acquisition, Explosives act, Indian electricity rules, Coal mine development and conservation act, Workmen's compensation act, Rescue rules, Mine accidents and occupational diseases, Accident statistics, Mine disasters management, Safety audit and conferences. This is more of safety management than engineering safety in mines . What is meant by engineering safety?
Safety is quality factor in a system Security Safety Survivability Defensibility System Asset Incident Incident Adaptation Protection Detection Reaction Trend Incident Incident Analysis Analysis Identification Factor Specific Subfactors Incident Reporting Counter Incident measure Logging improvement Service Degradation Service Restoration Safeguard Improvement Prosecution Common Quality Sub-factors of Defensibility (and therefore Safety) (after Donald Firesmith)
Quality Subfactors of Safety (after Donald Firesmith)
Requirements for Engineering Safety • Asset protection (also known as prevention and resistance) is the degree to which valuable assets are protected. Asset protection is classified into the following quality subfactors: o Harm protection is the degree to which the likelihood or amount of harm to assets is eliminated or decreased. o Safety incident protection is the degree to which the likelihood of safety incidents is eliminated or decreased. Safety incident protection is classified into the following quality subfactors: Accident protection is the degree to which the likelihood of accidents is eliminated or decreased. Near accident protection is the degree to which the likelihood of near accidents (also known as near misses) is eliminated or decreased. Note that a near accident is the occurrence of an unplanned event during the occurrence of a hazard that does not result in significant harm. o Hazard protection is the degree to which the likelihood of hazards (i.e., sets of hazardous conditions that can cause an accident) is eliminated or decreased. o Safety risk protection is the degree to which the likelihood of safety risks (typically maximum amount of harm multiplied by the likelihood of associated hazards) is eliminated or decreased. (after Donald Firesmith)
• Safety incident detection (also known as recognition) is the degree to which relevant safety incidents (or the harm that accidents cause) are recognized as they occur so that the system can react accordingly (e.g., to notify operators or safety personnel, to maintain essential services, to degrade gracefully). Safety incident detection is classified into the following quality subfactors: o Safety incident identification is the degree to which safety incidents (both accidents and near accidents) are identified as they occur. o Safety incident logging is the degree to which relevant information about safety incidents is logged as the safety incidents occur. • Safety incident reaction (also known as recovery) is the degree to which the system responds to a safety incident (e.g., recovers from an accident). Safety incident reaction is classified into the following quality subfactors: o Safety incident analysis is the degree to which safety incidents are properly analyzed in a timely manner. o Safety incident reporting is the degree to which logged (and possibly analyzed) safety incidents are properly reported in a timely manner. o Service degradation is the degree to which system services are properly degraded as a result of an accident (e.g., where practical, non-essential services are lost before essential services). o Service restoration is the degree to which system services are promptly restored after being lost due to an accident. o Prosecution is the degree to which the prosecution of malfeasance causing an accident is supported. Although this is more commonly a subfactor of security than of safety, it may be appropriate if gross negligence causes serious harm. (after Donald Firesmith)
• System adaptation is the degree to which the system adapts itself (based on previous safety incidents) so that in the future it may better protect its assets, detect safety incidents, and react to them. System adaptation is classified into the following quality subfactors: o Trend analysis is the degree to which the system tracks trends regarding the occurrence and impact of safety incidents. o Safeguard improvement is the degree to which the system improves its safeguards as a consequence of previous safety incidents and the result of trend analysis. Although few systems today are smart enough to automatically improve their safeguards, this safety subfactor may become more practical in the future. This safety subfactor is also more important when accidents are common, which is why countermeasure improvement (security) is more prevalent (i.e., security attacks are unfortunately common whereas major accidents are thankfully rare). (after Donald Firesmith)
Are these requirements for engineering the safety performance in industry addressed in our engineering curriculum? YES, however, not explicitly. Not in all disciplines equally. No specific evaluation and certification by registered body. How can it be incorporated? As core competency course in the professional curriculum. Delivered as a self learning course under cooperative learning/group learning using activities, industrial training, system development exercise etc.
OPTIONS: 1. Basic safety engineering and overview of disaster management in degree curriculum 2. Specific Professional Development / Master of Technology Course. A Safety Engineering Course was introduced as an elective subject in the Department of Mining Engineering, ISM Dhanbad in 1997. This was a first step in to consider mine safety management from command-and-control approach to investigate-and-engineer approach. The course was developed in consultation with DGMS which was during those days propagating the needs of paradigm shift in mine safety management. ANOTHER STEP IN MINING EDUCATION Department of Mining Engineering , IIT Kharagpur launched a Dual Degree Programme with B. Tech in Mining Engineering and M. Tech in Safety Engineering and Disaster Management in mines. The first batch of these programme was produced for the industry in 2010.
How to develop a Specialization Programme? apply knowledge Programe Outcomes design and conduct experiments analyze and interpret data mathematics design a system, M. Tech Programe component or process to impart ability to ensuring safety engineering function on multidisciplinary team identify, formulate and science solve engineering problems Field problems and Understand professional Existing technology and ethical responsibility deployment communicate effectively understand the global and social context become life long learner Input Use modern tools and skills OUTCOME
people money involves the use of equipment diverse resources materials information technologies resolves conflicting technical, engineering or other issues. Disaster engineering Management involves creative science and innovative use of knowledge humanities considers consequences in Societal wide range of context Involvement
Delivery of the Curriculum An approach for curriculum delivery E-learning, Student centered learning Cooperative learning Life long learning Problem based learning Analytic learning Demonstrative learning Next? Work based learning
Knowledge Comprehension Application Analysis Synthesis Evaluation LEARNING OBJECTIVES Delivery Modes: Lectures, Labs, Field Trip, Activity STUDENTS Instructions LEARNING ASSESSMENT E-learning, Student centered learning Traditional: Test, Quiz, Cooperative learning Survey Life long learning E-assessment Problem based learning Analytic learning Demonstrative learning Work based learning
Outcome of a Safety Engineering and Disaster Management Programme At the end of the Safety Engineering and Disaster Management programme the student should be able to: • Think critically and be able to analyze and solve complex, real- world problems related to Safety and Disasters • Find, evaluate and use appropriate learning resources of this specialization • Work cooperatively in teams and small groups to define problems and to explore solutions of • Demonstrate versatile and effective communication skills, both verbal and written for defined communication targets • Use content knowledge and intellectual skills acquired at the university to become continuing learners
RESEARCH AND KNOWLEDGE MANAGEMENT: Mining Disaster , Natural and Manmade Geotechnical Disaster Mining Disaster , Natural and Manmade Geotechnical Disaster DGMS (i)Systematic inventorization of disaste carries (ii)Trend analysis and reporting out NIDM Mining Engg Department, IIT KGP participates develops Initiates Develop national 1. Technical Analysis disasters database 2. Evaluation of technology 3. Assessment of research needs 4. Development of alternatives 5. Interactions with other national and International academia
What the HR developed for Safety Management will serve?
Safety Engineering Competency To identify Sources of Accidents… where you are at risk Machinery guarding. Clearing blocked or stalled crushers. Slips and trips. Plant maintenance. Working at heights. Comply the Requirements of act/law/code of practice: PREVENT WORKERS FROM ACCESSING MOVING PARTS How do they do that?
Designing Guards: e.g. Conveyor belt drive drum, end pulley, crusher, shaft, electrical installations Guards prevent access to drum and rollers that could result in degloving injuries, fractures or amputation. Characteristics of Guard • A guard is a direct physical barrier • A guard makes it impossible for a person to put any part of their body through, around, over or under it in order to reach a dangerous part of any plant. • A guard should be interlocked, where opening the gate automatically shuts the plant down; or padlocked, with a written procedure put in place specifying that the plant must be stopped and isolated before accessing it.
Modern Guard-Safety Light Curtain : A photoelectric transmitter projects an array of synchronized, parallel infrared light beams to a receiver unit. When an opaque object interrupts one or more beams the light curtain controller sends a stop signal to the guarded machine.
Modern Safety Approach Traditional approach – Accident prevention Focus on outcomes (causes) Unsafe acts by operational personnel Attach blame/punish for failures to “perform safely” Address identified safety concern exclusively Identifies: WHEN? WHAT? WHO? But not always discloses: WHY? HOW?
Accident causes - a concept Organization Workplace People Defences Accident Latent conditions trajectory Source: James Reason
The organizational accident Organizational processes Organizational processes Improve Identify Monitor Workplace Workplace Latent Latent conditions conditions conditions conditions Reinforce Contain Active Active Defences Defences failures failures
Understanding deviations? Incident Production objective(s) Accident High Violations Technology People Safety Risk space Training Procedures Low Max. System output Min.
Three options Organizations and the management of information Pathological – Hide the information Bureaucratic – Restraint the information Generative – Value the information Source: Ron Westrum
Three organizational culture types Pathological Bureaucratic Generative Information Hidden Ignored Sought Shouted Messengers Tolerated Trained Shirked Responsibilities Boxed Shared Discouraged Reports Allowed Rewarded Covered up Failures Merciful Scrutinized Crushed Problematic Welcomed New ideas Resulting Conflicted “Red tape” Reliable organization organization organization organization Source: Ron Westrum
Objective of an organization? MUST NOT NEGLECT SAFETY!
The essential is invisible to the eyes Number of occurrences 1 1 – 5 Accidents 30 30 – 100 100 Serious incidents 100 100 – 1000 1000 Incidents Latent conditions 1000 1000 – 4000 4000
Safety management System FRAMEWORK Safety policy and objectives 1.1 – Management commitment and responsibility 1.2 – Safety accountabilities of managers 1.3 – Appointment of key safety personnel 1.4 – SMS implementation plan 1.5 – Coordination of the emergency response plan 1.6 – Documentation Safety risk management 2.1 – Hazard identification processes 2.2 – Risk assessment and mitigation processes 2.3 – Internal safety investigations Safety assurance 3.1 – Safety performance monitoring and measurement 3.2 – The management of change 3.3 – Continuous improvement of the safety system Safety promotion 4.1 – Training and education 4.2 – Safety communication
The final objective Safety programme + SMS = State integrated safety management system Protection Production Objective: State Public safety safety programme Oversight Acceptance Oversight Objective: Organization’s Achieve Objective: Organization’s safety commercial Manage and production goals and control management processes customer safety risk Risk management system (SMS) satisfaction Safety assurance
The safety management process Identify hazards Collect Re-evaluate Assess additional control hazard risks strategies data Implement Prioritize Safety control risks strategies management process Develop elimination/ Assign Approve mitigation responsibilities control strategies strategies
Operations Intelligence Approach Operations Intelligence (OI) Production Observed Results compares Acceptable vs. Rejection Data of Process results from a production process Acceptab Rejectio Parameter le n Historical data of the production process Results Results s Decipher why a process produces acceptable quality or rejection quality Use logic based machine learning algorithms. Operations Intelligence Good Practice Rule Risk Situation discovered… Explains discovered… Explains the the conditions of conditions of which parameter combination to which parameter be avoided to prevent combination gives reject quality acceptable quality
Analysis using Operations Intelligence Further data collection & refinement at periodic intervals by Trained teams 1 2 3 4 Data Import 1. Identify Patterns Refine Implement process monitoring using 2. Form Best Practice Rules Rules Virtual Quality Gates 3. Form Bad Practice Rules Patented
How to use COLLECTIVE INTELLIGENCE OF THE COMPANY for zero accident production enhancement? How company can create new possibilities for action? Can hyper-specializations bring synergy to collective intelligence for company’ss business? Just as smartphones, online shopping sites, and music apps learn and adapt based on our preferences, cognitive computing can be used to teach computers to recognize and identify risk. with cognitive analytics, computers have the ability to learn. The use of Enterprise Artificial Intelligence to manage risk is going to be particularly helpful when handling and evaluating unstructured data — the kind of information that doesn’t fit neatly into structured rows and columns. Cognitive technologies will help to anticipate and proactively manage risk to gain competitive advantage and use risk to power their organizations’ performance.
Small things big results RENAME SAFETY DEPARTMENT AS SAFETY ENGINEERING DEPARTMENT Safety Engineering Activities Safety Program Planning This task is to develop the safety program for the mining unit operations by: Identifying safety work units including tasks and techniques Identifying safety work work products (documents) including plans and reports Identifying safety producers i.e safety engineering experts including their roles and teams Balancing the needs for safety with the needs for productivity. Safety Risk Analysis This task is to analyze and document the safety risks involved in different operations. Evolving procedures for evaluating safety risks for all its operations, worksites and machinery. Incident Investigation To find the causes and to make strategy for future elimination of similar incidents. Safety Monitoring Check compliance of the unit operations with the safety program. Monitor current safety task performance. Evaluate current state of safety work products. Document the current status of the safety program in the safety status report. Update the safety compliance repository, where all safety information is properly and securely documented
Safety Compliance Assessment (during the entire life cycle ) Identify or determine the safety-related or safety-critical components of the application. Determine the safety integrity levels of these components. Determine the way these safety-related or safety-critical components fulfil their safety requirements and achieve their safety integrity levels. Determine the means by which the fulfilment of these requirements and the achievement of these safety integrity levels will be verified (e.g., analytical arguments, safety testing). Analyze the inclusion of commercial off-the-shelf (COTS) or reused components with regard to safety. Safety Certification
ACHIEVING SAFETY GOALS THROUGH.. Accepted Safety Norms Safety Ensured Technology (SET) Risk Free Design Failure Free Application Practicing Safety Engineering Safety engineering involves integrated execution of number of interrelated tasks to ensure trouble free performance of various mining tasks Hazards still may occur and technology for hazar management must be in place
A hazard is anything that has the potential to cause injury or illness. Hazards in the workplace can include: Physical - examples : Chemical - examples : * noise and vibration * dangerous goods and chemicals * temperature and humidity * poor ventilation, which can cause * poor ventilation problems with dust, fumes, * poor lighting vapours, gases and liquids. * untidiness Environmental - examples : Human behaviour - examples : * condition and design of * boredom equipment and furniture * distraction * occupational overuse * interpersonal interactions injuries such as incorrect * aggression lifting. * communication problems
Identifying and reporting hazards There are several ways to identify hazards in the workplace, including: • Inspections and audits • Hazard reports • Job analysis • Health monitoring data • Material safety data sheets • Workplace environment monitoring data UNELIMINATED HAZRDS CAN CAUSE DISASTER
Recovery from Industrial Disaster
DISASTERS Extreme Events…… …….Surprise Events
DISASTERS Seldom Isolated Modern society is served by interconnected industries
MINING OPERATIONS PROGRESS….. Through controlling disasters……. Chasnala, Mahavir or Bhagadih are SURPRISES
Mining Disasters • Sudden in-rush of large amount of water to an underground working face • Firedamp or coal dust explosions • Underground mine fire • Sudden release of toxic gas in mines • Collapse of gallery roofs • Major machinery failure like winder failure, dump-truck fire • Breakage of tailing dams • Spoil dump failure • Radiation hazards of radioactive tailings or fly-ash
Mining Disasters EMERGENCY RESPONSE PLAN COME WHAT MAY………We are ready!
KEY ELEMENTS FOR EMERGENCY RESPONSE • Specific procedures to respond to, mitigate and recover from emergencies; • The chain of command in an emergency within the mining organizations and its links with local emergency response units; • A communication protocol to ensure that accurate and up-to-date information is provided to the surrounding community on a timely basis; • Defined roles and responsibilities for those assigned to respond in an emergency.
EMERGENCY PLAN : NEEDS OF EVERY MINE What is there in an Emergency Plan? A. Preliminary Action: • Preparation of the plan, to meet special requirement of site, production and surrounding • List of key telephone number • Provisions for emergency lighting, and other special kits • Familiarization of every staff with the detail plan of the site • Training of key personnel involved to develop key personnel • Notes on specific hazards • Plan of site showing shelter and exit routes • Designation of escape routes • Initiation of a programme of inspection of potentially hazardous areas, testing of warning system and evacuation procedures • Stipulating specific periods at which the explanation is to be reexamined and update
What is there in an Emergency Plan? B. Action when emergency is imminent • Warning of the emergency • Assemble key personnel • Review standing arrangement • Test all systems C. Action during emergency • Precise and rapid judgment of the key persons • Prepare actions quickly D. Ending the emergency • To declare safe • Resume work • Restoration of normalcy E. Capacities and Vulnerabilities Analysis
DISASTER RECOVERY PLAN Set of agreed upon procedures to minimize the effects of disaster on the operations of the organization EMERGENCY RESPONSE PLAN Immediate Solution DISASTER RECOVERY PLAN Getting back to the normal operations MUST BE WORKABLE ON SHORT NOTICE AT ANY TIME
DISASTER RECOVERY PLAN Contents Specification of responsibilities for different personnel both for situations before disaster and after disaster. Definitions of basic approach Statements of assumptions for defining responsibilities and actions Fixation of priorities to different disaster mitigation works Identifying the areas of particular concern
DISASTER RECOVERY PLAN Takes Care of Areas of Disaster Exposure Financial loss Legal responsibility Business service interruption
Components of Disaster Recovery Plan 1. Assumptions and considerations 2. Recovery requirements 3. Description of Resources and critical resources 4. Strategies considered and recommended strategy 5. Detailed Recovery Procedures 6. Emergency Plan and Backup Plan 7. Staffing Responsibilities 8. Maintenance and Testing Procedures 9. Recommended Actions 10. Restoration Procedures 11. Documentation and Related Information
Needs Evaluation 1. Legal obligation requirement 2. Cash flow maintenance 3. Customer Servicing 4. Competitive Advantages 5. Production and Distribution Decisions 6. Logistics and Operation Control 7. Ongoing Operation Control 8. Organization Image and Public Relation
REQUIREMENTS FOR DEVELOPMENT AND MAINTENANCE OF DISASTER RECOVERY PLAN Organizational commitment: The mines must be committed to provide : Funding Staffing Management interest Periodic testing of the plan Policies and program: The mines must have clearly adopted policies regarding: Fire protection equipment installation and maintenance Emergency alarm procedures Fire monitoring and training Emergency control centers Rescue operation centers Rescue training and rescue apparatus for disaster mitigation crew Mock Rehearsal policies for emergency situations
REQUIREMENTS FOR DEVELOPMENT AND MAINTENANCE OF DISASTER RECOVERY PLAN Study and Planning Group: Mines must deploy a study and planning group to keep the preparedness to meet the probable disaster Internal Safety Auditing: The mines must incorporate internal safety auditing for the following purposes: Review vital record requirement for planning disaster recovery Review risk analysis procedures and principles Plan the management of resources for disaster
Immediate Requirement of a Mine Manager: A CHECKLIST ! Disaster recovery preparation checklist No Item Y/N NA 1 Have all staff been trained for all possible disaster 2 Do all staff know what they should do when an alarm rings? ie they should go to safer place Do not return to pick up items from workplace Report to supervisors at designated place. 3 Do all staff knows who to call in the cases of emergency and do they know where the telephone list is located? 4. Do the disaster recovery team understand that the protection and safety of the people is the first priority? 5 Has the management notification procedures been developed for any emergency of any size?
Disaster recovery preparation checklist No Item Y/N NA Maintenances of services and cash flow 6 Has the management strictly prioritized the most necessary services to be maintained in an emergency? 7 Can an alternate operation be brought up within 24 hours? 8 Does the organization has plan for controlled public press releases in terms of disaster? Protection of vital document 9 Have the vital documents are protected? 10 Is there any legal factors in documents procedure
Disaster recovery preparation checklist No Item Y/N NA Protection of facilities and equipment 11 Is the equipment maintained and condition recorded 12 Is there a complete list of assets
Disaster Recovery Plan COMPANY MUST HAVE A DECLARED POLICY Definition Phase Decide objectives Appoint staff Develop institutive and assumptions Decide the disaster to be monitored Key disaster scenario. Financial Requirements Analyze application facilities Set priorities Design and Development Evaluate alternative Implementation Phase Testing and monitoring Back-up arrangements Maintenance
Contents of Disaster Recovery Planning Objectives and Assumptions Fact Gathering and functional requirements Evaluation of Alternatives Development of Plan Post Development Review Updating the Plan
Documentation for Disaster Recovery Plan Facility Layout Site plans Floor plans Route plans Facility plans Organization chart and phone number List of important contacts Emergency warning system Assigned Responsibilities First Aid and Rescue Management Guidelines and Instruction sheets
Safety Data Sheet Identification of dangerous substances, dangerous sites or dangerous appliances Compositional and other details of the above dangerous possibilities Hazard identification First aid measures for the probable hazards Fire fighting measures Accidental release measures Handling and storage of hazardous substances if any Exposure control through personnel protection Physical and chemical properties of the dangerous substances Stability and reactivity Detailed toxicological information Ecological information of the mine site Waste Disposal consideration Transport information for the pollutants Regulatory information of CMR, MMR, etc.
DISASTER AUDITING Every mine should be audited for determining disaster potential
ADVANCED TECHNOLOGY SUPPORT TO SAFETY ENGINEERING VIRTUAL REALITY FOR MINE OPERATION AND SAFETY Virtual reality (VR) involves computer simulations that use 3-D graphics and devices such as the Dataglove to allow the user to interact with the simulation. VR for the safe planning of the installation of mine equipment and to use as a tool in the investigation of mine accidents. VR training software is now being developed by which the miners will be able to receive accurate training in hazard recognition and avoidance. The VR software may allow miners to follow mine evacuation routes and safe procedures without exposing themselves to danger.
Ergonomics and Remote Control for Safe Mining Comfort methodology is implemented for design and maintenance of the machinery. The methods are the combination of: an extended scale of objective and subjective test methods integration of short-term and long-term comfort measurements testing under controlled conditions Safety and productivity increases by making the right choice of a seat or cabin resulting less discomfort, tiredness and complaints improving achievements from operators and drivers
New Technology for Safety Enhancement Certain technology that has increased mine safety are: • Fire suppression system • Technology to control methane gas levels • Emergency breathing devices • Ventilation Techniques • Dust suppression techniques with sensitive dust measurement instruments
Requirements of advanced technology underground drilling systems for gas drainage safety equipment & personal protection portable electronic gas monitoring equipment comprehensive environmental monitoring routine condition monitoring systems for fans and plant monitoring and control systems for extraction and utilisation plant gas cleaning and conditioning power generation packages gas prediction and real time gas emission monitoring software and support alarm and evacuation system Underground communications particularly for isolated workers and in an emergency situation
Information technology and management information systems Underground Communication Technology Enhancing Safety around Mobile Plant by examining personnel proximity detection, location and warning annunciation methods
Information technology and management information systems Underground Communication Technology Enhancing Safety around Mobile Plant by examining personnel proximity detection, location and warning annunciation methods
System Approach for Safety Enhancement safety is considered as an emergent property of systems that arises from the interaction of system components Safety can only be determined by the relationship between the valve and the other plant components — that is, in the context of the whole. Safety Engineering Sub-systems Design engineering Human engineering Reliability Engineering Maintainability Engineering Test Engineering Product support Production engineering Industrial coordination Training
Safety Systems Functions 1. Documentation of the system safety approach; 2. Identification of hazards; 3. Assessment of mishap risk; 4. Identification of mishap risk mitigation measures; 5. Reduction of mishap risk to an acceptable level; 6. Verification of mishap risk reduction; 7. Review of hazards and acceptance of residual risk; and 8. Hazard tracking, their closures and residual risk. To carryout these tasks safety database and information technology contribute to a great extent. Advances in Geographic Information system (GIS) have brought new revolution in system safety enhancement. GIS can be used for Risk Zoning as well as hazard mitigation programmes.
GIS for Subsidence Management Risk induced by the presence of a mine and assets on the ground surface
Surface impacts due to mining collapse. Example of a house damaged by mining subsidence (Auboué, France, 1996).
GIS Overlay Analysis for Safety Zoning
Spatial Analysis Output for Safety Supervision
Operational Safety Management in Surface Mine Blasting Spatial Information of Map Attributes in GIS
Area Buffering in GIS to visualize area of danger
Line Buffering in GIS to manage risk of mine inundation
GIS for Decision Support : an example Graphical Window Query Window Query Result Window
CONCLUSION Management of safety in mines is possible only through selection of appropriate technology for exploitation as well as by engineering safety. Developments in different branches of engineering are to be incorporated in mine safety management programmed. Instrumentation, tele-monitoring and information technology including virtual reality (VR), remote sensing (RS) and GIS are the tools for accomplishing the mission of safe mining in the near future. Indian mining industry, interdisciplinary academics and the safety enforcing officials need to resolve without further delay to come forward together in collaborative R&D work for application development to avoid continuing to be a technology importer in this area.
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