Engineering Prof. Khanindra Pathak Mining Engineering Department - - PowerPoint PPT Presentation
Lecture for Safety Symposium & Exposition on 9 August 2017; ITC Sonar, Kolkata Advanced Technology for Safety Management and HRD for Safety Engineering Prof. Khanindra Pathak Mining Engineering Department IIT KHARAGPUR Flood as disaster
Lecture for Safety Symposium & Exposition on 9 August 2017; ITC Sonar, Kolkata
Flood as disaster can affect a large area in India
Natural Disaster area and mining areas of India
What is Good Business Practice?
Good safety practice very visible way of showing that you do value the people you work with REWARD Safe and more productive workplace
ENGINEERIN G EDUCATION
involves teaching of technology engineering teaching at Polytechnics Schools Industrial Training Institutes Engineering colleges Technical Institutes and universities Special Purpose Institutes use their knowledge of science, mathematics, and appropriate experience to find suitable solutions to a problem produces Engineers who find ways to use natural resources to create wealth need predict and handle natural and anthropogenic disasters Industrial workers natural and anthropogenic disasters
HRD for Safety Engineering
How does our engineering curriculum addresses Industrial Safety and Disasters Natural Disasters Assumption: Students with good understanding of
science and engineering principles can be trained for any industry or for any technical job.
How are the safety and disasters professional raised in India? Do we have adequate safety and disaster professional in India? Have we created proper cadre for the safety and disaster professionals in the industry and civil administration departments ?
XII and there is scope to provide exposure to atmospheric physics or Ocean studies
adopting career of safety engineer
training
exposure, industry can not avoid training needs
by training
number
drills
need to be planned and integrated
atmosphere
high risk and emergency jobs
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aftermathnews.wordpress.com/category/biometrics/ www.textually.org/textually/archives/2009/02/?p=6
users.static.freeblog.hu/.../IndianTrain2.jpg
www.sulekha.com/.../default/train%20accident.jpg
1981 : Train avoids cow, but kills 600 More than 500 passengers are killed when their train plunges into the Baghmati River in India
Railway recruits the best engineers, and has huge in house professional development system. Who investigates its adequacy? The Indian railway system is one of the safest in the world today. However, disasters are not ruled out.
im.rediff.com/news/2003/jul/03inter.jpg
http://bengalnewz.blogspot.com/ Villagers look on bleakly as the Jamuna River continues devouring areas in Sariakandi upazila of Bogra district. breached embankment in the Puthimari area, Assam Who and How will Fight Natural Disaster (anthropogenically induced?)
Mine fire at Sangramgarh near Asansol , out of the ratholes, dug by illegal miners Dr Hartwig Gielisch, German geologist is investigating quenching underground mine fire at Asansol and wants to take mitigation
at Jharia Coalfield. Mine fire is more than a disaster. At Satgram in the Asansol coal belt , smoke started coming out of three illegal coal mines, 3.1.2008 A future disaster by mining if neglected
www.daylife.com/photo/0bb2bOpcNg49r
Another disaster in making! 3.1. 2008 due to Illegal mining. A bye-product of management of law and order by Communist Govt. in West Bengal www.daylife.com/photo/0c5K0Qv5M26x1
A massive fire broke out in Kunustoria Colliery of Eastern Coalfield Limited (ECL) around 6 pm on Thursday, 29 October 2009. Locals heard a loud explosion inside the mine, located about 20 km from Asansol. Photo : Niraj Modi
Market of Safety Gadgets, safety monitoring sensors, safety management software, safety data analtytics Since there is less social and institutional awareness the market for safety gadgets as well as motivation for innovations in developing safety gadgets are not visible in India. We are used to see: 1. Long ladder carried by two electricians on bicycle and going to attend elelctrical fault. 2. Electricians on hawai chappals and climbing poles without safety belt 3. Narrow roads with 1 feet deep solder and curves without super elevation 4. Passengers on bus top, train roof, foot boards Awareness to safety through quality of life can create market for safety gadgets and tools in India and there may be a possibility of multi-million business in this sector with stake holders from education, industry and many other spheres of life. Scopes of innovation through exploration of rural India: Safety and Disaster Management will require Application of Science and Technology. Should India design an undergraduate curriculum for B. Tech (Safety Engineering)? INDIA needs educational and HRD programmes for Safety consciousness for engineering sa
Mining Engineering.
become manager of mines. T
underground mines.
courses
technology for mining SAFETY AND MINING ENGINEERING DISCIPLINE. Safety provisions to be maintained in mines are stipulated by:
Directorate General of Mines Safety has statutory power to inspect and demand implementation of safety standard in mines. Should such compulsions be there for Civil Engineers joining PWDs, Road and Dam Construction Should engineering ethics be a compulsory component of engineering education?
Government of India (GOI) on 4th March, 1966 to generate, develop and sustain a voluntary movement on Safety, Health and Environment (SHE) at the national level. It is an apex nonprofit making, tripartite body, registered under the Societies Registration Act 1860 and the Bombay Public Trust Act 1950. Its role is limited. No statutory power to close unsafe practices. No industry specific roles. It is common forum for policy discussion and a suggesting body. Kerala Cabinet decided in December 2004 to set up a Road Safety Authority to bring down accidents. Dock Workers (Safety, Health and Welfare) Regulations, 1990. NDMA has been formed. Institutions like NDMI has been developed. More Regulatory and Institutional efforts have started in India e.g.
Directorate General of Mine Safety, Directorate General of Civil Aviation Directorate General, Factory Advice Service and Labour Institutes (FASLI), Mumbai (less than 150 officers of this organisation looks after safety besides other things for factories, docks and
construction safety) Regional Labour Institute, Chennai Regional Labour Institute, Kanpur Regional Labour Institute, Kolkata Regional Labour Institute, Faridabad
We may have in future:
(Turkey has such directorate under Ministry of Transport)
These statutory authority will have to work not only as an approving authority but a implementation partners Implementation of Industrial safety in India
The graduate engineers of all discipline should have a compulsory safety and disaster related paper specific to the discipline . Practicing engineers in specific industrial sector must have departmental competency examination system under various directorate for taking up positions of managerial authority. IAS or State Civil Service officers should be made in-charge of safety and disaster management related activities after they clears similar Departmental Proficiency Certification or special training. Only mining industry has such system, and it is the industry with a very good safety records in spite of being a hazardous industry.
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.
What is meant by engineering safety?
Common Quality Sub-factors of Defensibility (and therefore Safety) (after Donald Firesmith) Safety Security Survivability Defensibility Asset Protection Incident Detection Incident Reaction System Adaptation Factor Specific Subfactors Incident Identification Incident Logging Incident Analysis Incident Reporting Service Degradation Service Restoration Prosecution Trend Analysis Counter measure improvement Safeguard Improvement Safety is quality factor in a system
Quality Subfactors of Safety (after Donald Firesmith)
Safety incident protection is classified into the following quality subfactors:
decreased.
known as near misses) is eliminated or decreased. Note that a near accident is the
significant harm.
cause an accident) is eliminated or decreased.
multiplied by the likelihood of associated hazards) is eliminated or decreased.
Requirements for Engineering Safety (after Donald Firesmith)
that accidents cause) are recognized as they occur so that the system can react accordingly (e.g., to notify operators
the following quality subfactors:
identified as they occur.
incidents occur.
safety incident (e.g., recovers from an accident). Safety incident reaction is classified into the following quality subfactors:
manner.
properly reported in a timely manner.
accident (e.g., where practical, non-essential services are lost before essential services).
to an accident.
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)
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:
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.
Programe Outcomes mathematics science engineering
to impart ability to
apply knowledge design and conduct experiments analyze and interpret data design a system, component or process ensuring safety function on multidisciplinary team identify, formulate and solve engineering problems Understand professional and ethical responsibility communicate effectively understand the global and social context become life long learner Use modern tools and skills
Field problems and Existing technology deployment Input OUTCOME How to develop a Specialization Programme?
involves the use of diverse resources people money equipment materials information technologies resolves conflicting technical, engineering or
involves creative and innovative use of knowledge engineering science humanities
considers consequences in wide range of context Societal 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 Work based learning
Next?
LEARNING OBJECTIVES Instructions LEARNING ASSESSMENT STUDENTS
E-learning, Student centered learning Cooperative learning Life long learning Problem based learning Analytic learning Demonstrative learning Work based learning Delivery Modes: Lectures, Labs, Field Trip, Activity Traditional: Test, Quiz, Survey E-assessment Knowledge Comprehension Application Analysis Synthesis Evaluation
At the end of the Safety Engineering and Disaster Management programme the student should be able to:
world problems related to Safety and Disasters
specialization
and to explore solutions of
verbal and written for defined communication targets
university to become continuing learners Outcome of a Safety Engineering and Disaster Management Programme
RESEARCH AND KNOWLEDGE MANAGEMENT: Mining Disaster , Natural and Manmade Geotechnical Disaster Develop national disasters database (i)Systematic inventorization of disaste (ii)Trend analysis and reporting
DGMS carries
Mining Engg Department, IIT KGP Initiates 1. Technical Analysis 2. Evaluation of technology 3. Assessment of research needs 4. Development of alternatives 5. Interactions with other national and International academia participates develops Mining Disaster , Natural and Manmade Geotechnical Disaster
What the HR developed for Safety Management will serve?
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?
Guards prevent access to drum and rollers that could result in degloving injuries, fractures or amputation.
Characteristics of Guard
around, over or under it in order to reach a dangerous part of any plant.
plant down; or padlocked, with a written procedure put in place specifying that the plant must be stopped and isolated before accessing it. Designing Guards: e.g. Conveyor belt drive drum, end pulley, crusher, shaft, electrical installations
Modern Guard-Safety Light Curtain: A photoelectric transmitter projects an array of synchronized, parallel infrared light beams to a receiver unit. When an
stop signal to the guarded machine.
Defences Accident
Source: James Reason
Latent conditions trajectory People Workplace Organization
Accident
Violations
Source: Ron Westrum
Hidden Ignored Sought Shouted Tolerated Trained Shirked Boxed Shared Discouraged Allowed Rewarded Covered up Merciful Scrutinized Crushed Problematic Welcomed Conflicted
“Red tape”
Reliable
Pathological Bureaucratic Generative Information Messengers Responsibilities Reports Failures New ideas Resulting
Source: Ron Westrum
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
State safety programme Organization’s safety management system (SMS) Organization’s production processes
Objective: Public safety Objective: Manage and control safety risk Acceptance Oversight Objective: Achieve commercial goals and customer satisfaction Risk management Safety assurance
Oversight
Re-evaluate control strategies Implement control strategies Assign responsibilities Approve control strategies
Safety management process Identify hazards Assess risks Prioritize risks Develop elimination/ mitigation strategies Collect additional hazard data
Good Practice Rule discovered… Explains the conditions of which parameter combination gives acceptable quality
Risk Situation discovered… Explains the conditions of which parameter combination to be avoided to prevent reject quality
Operations Intelligence
Operations Intelligence (OI) compares Acceptable vs. Rejection results from a production process
Historical data of the production process Decipher why a process produces acceptable quality or rejection quality Use logic based machine learning algorithms.
Observed Results
Acceptab le Results Rejectio n Results
Production Data of Process Parameter s
1 3 4 2
Data Import 1. Identify Patterns 2. Form Best Practice Rules 3. Form Bad Practice Rules Refine Rules
Implement process monitoring using Virtual Quality Gates
Further data collection & refinement at periodic intervals by Trained teams
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
Cognitive technologies will help to anticipate and proactively manage risk to gain competitive advantage and use risk to power their organizations’ performance.
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
Small things big results
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 Safety engineering involves integrated execution of number of interrelated tasks to ensure trouble free performance of various mining tasks Practicing Safety Engineering Hazards still may occur and technology for hazar management must be in place
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
UNELIMINATED HAZRDS CAN CAUSE DISASTER
Seldom Isolated
Modern society is served by interconnected industries
Chasnala, Mahavir or Bhagadih are SURPRISES
COME WHAT MAY………We are ready!
links with local emergency response units;
provided to the surrounding community on a timely basis;
EMERGENCY PLAN : NEEDS OF EVERY MINE What is there in an Emergency Plan?
system and evacuation procedures
What is there in an Emergency 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
Fixation of priorities to different disaster mitigation works
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 Identifying the areas of particular concern
Takes Care of Areas of Disaster Exposure Financial loss Legal responsibility Business service interruption
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
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
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
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
Immediate Requirement of a Mine Manager: A 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
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 preparation checklist No Item Y/N NA
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
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
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:
Requirements of advanced technology
support
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. Design engineering Human engineering Reliability Engineering Maintainability Engineering Test Engineering Product support Production engineering Industrial coordination Training Safety Engineering Sub-systems
Safety Systems Functions 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
Spatial Information of Map Attributes in GIS Operational Safety Management in Surface Mine Blasting
Area Buffering in GIS to visualize area of danger
Line Buffering in GIS to manage risk of mine inundation
Query Window Graphical Window Query Result Window
GIS for Decision Support : an example
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. CONCLUSION
Conveyor Belt Safety
inspections, cleaning up or maintenance work .
Indirect hazards:
dust, noise, rotating/moving parts
Necessary for Safe Practice Conveyor belt
at every dangerous part of a conveyor normally accessible to personnel
walkway
the conveyor to stop in the event of their being pulled in any direction, breaking, slackening or removal
be: * Red * Prominently marked * Readily accessible * Mushroom head latch in or lock in with manual reset.
(inaccessible to persons) an emergency stop button must be located every 100m.
Power transmissions Nip points Shear points Pinch points Spill points Areas under counterweights Transfer counterweights Transfer mechanisms Passage areas under conveyor Under special circumstances Typical Conveyor Hazard Points Keep Employees Involved for Maximizing Safety
Sources of danger in a conveyor belt
Potential Dangers
exposed drive shafts belt takeup or tensioning devices skirting or scraper arrangements belt drive arrangement exposed idlers in combination with skirts Tail Drum and Head Drum Arrangements
Rendering Belt Conveyor Safe
1. Direct Physical Guarding 2. Indirect methods (procedures, training, signage etc.)
Principle of Providing Guards Considerations for Providing Gate and Fence
Gate dimensions so that people can’t reach over the top or slide underneath to reach conveyor Mesh size correctly so people can’t climb Padlock or interlock mechanism A p p ro p r i a t e danger signs (for example: no entry while plant is running)
Ensure that:
Guarding Regular Access Area eas needing regular access should be adequately guarded considering:
People will sometimes try to reach through, over, around or under guards to avoid stopping the belt for a quick job. Guards should be built such that this is not possible to do!
point must have mesh smaller enough to disallow fingers or hands to reach the nip point.
install or remove for maintenance. Where possible, a self supporting guard should be used to eliminate any manual handling hazard.
Tail & Head Drum Guards: Tail and head drums are one of the most hazardous sections of a conveyor with access being required occasionally for lubrication, belt alignment, spillage cleanup and condition monitoring. Key issues to watch out for with tail drum guards are:
Tail drum nip point must be physically impossible to reach!
Idler and skirt guards
Upright swinging hinged guard Downward swinging hinged guard
return idler guard. belt drive guard
back of the belt drive)
accidentally access the belt drive Belt Drive Guard
Indirect Safety Measures Training & Inductions Awareness of no entry areas Awareness of correct safety apparel i.e. personal protective equipment (PPE)
Awareness of emergency stop mechanisms Awareness of basic safety procedures
Procedures & Standards
example of an isolating mechanism
Eliminate spillage, the source of many conveyor incidents Spillage around tail drums, mud building up on idlers and so on often require guards to be taken off so that the spillage can be cleaned up. It is in these situations where if the job is a quick one, the temptation to not go through the correct procedure and isolate the belt is high. The use of good skirts and scrapers will reduce how often you will need to clean up around the belt, and this fact alone will reduce the exposure of people to the belt and hence make it safer.
Housekeeping Standards
is to be cleaned up immediately.
when the conveyors aren’t running)
not lying around on walkways or leaning loosely against handrails.
Always Be Aware:
Unless nip points are completely guarded and inaccessible, no cleaning is to be undertaken under or in the close proximity of belts unless the belt is turned off and isolated. Lubrication points should always be positioned outside the guards and be remote to the nip points with the use of tubes. If this is not possible, then the belt should be isolated during any lubrication activities. If you're going to have standards you must be prepared to enforce them. Remember, the minimum standard that is set is the highest standard most people will work to.
Signage
where somebody could do something to create a hazardous situation. Typical situations include:
must be worn beyond this point
Warning: isolate belt before removing guards. Care must be taken when placing signs to ensure that they are relevant for the area and do not contradict each other.
To avoid spillage: Skirt Board
Reach & other key dimensions (as per AS 1755)
Minimum distance above floor before guarding of nip points is not required: 2500 mm Minimum distance of guard from danger point if mesh opening is up to and including 9mm: Working clearance only Minimum distance of guard from danger point if mesh opening is above 9mm up to 50mm square: 150 mm Minimum distance of guard from danger point if it is possible to get wrist through the mesh or guard: 280mm Minimum distance of guard from danger point if it is possible to get elbow through the mesh or guard: 500mm Minimum distance of guard from danger point if it is possible to get entire arm through the mesh or guard: 1000mm Maximum distance of underside of guard from the floor (in the case of gates, fences
250mm Maximum size of mesh (in the case of gates or fences ): 50mm2 Minimum height of fencing: 1600mm
Emergency Stop Locations Maximum distance between emergency stop locations if conveyor is accessible: 30m Maximum distance between emergency stop locations if conveyor is inaccessible: 100m Maximum distance between supports for lanyard emergency stop mechanism: 4.5m
Don’t perform service on conveyor until motor disconnect is Locked Out! Service conveyor with only authorized maintenance personnel. Keep clothing, fingers, hair, and other parts of the body away from conveyor! Don’t climb, step, sit or ride on conveyor at any time! Don’t load conveyor outside of the design limits! Don’t remove or alter conveyor guards or safety devices! Know location and function of all stop/start controls. Keep all stopping/starting control devices free from obstructions. All personnel must be clear of conveyor before starting. Operate conveyor with trained personnel only! Keep area around conveyors clear of obstructions. Report all unsafe practices to supervisor!
Fundamental Rules for Belt Conveyor Safety
Risk Assessment Table
LIKELIHOOD Almost Certain Likely Possible Unlikely Rare CONSEQUENCES Extreme Extreme Extreme Extreme High Extreme Extreme Extreme High High Extreme High High Medium Medium High High Medium Low Low High Medium Low Low Low Catastroph ic Major Moderate Minor Insignifica nt
Eliminate Substitute Engineering Administrative Wearing PPE
Safety is everyone’s responsibility It’s a team effort How do we measure and manage a Safety Culture? Culture is the way we do things.
Dust Do you wear the same clothes at work place at home: you increase the risk of your family inhaling airborne dusts. Don’t we need a booth in the mine to dedust our clothes without making us to inhale the dusts.
Stockpile and Dump Safety
and quarrying industry Companies should include written safe work procedures in induction systems for truck drivers and FEL operators. They must be made aware of the hazards and understand fully each company’s safe work procedures at that quarry.
This incident could have easily been avoided using the SAFE approach.
edge, causing damage to plant and personal injury
use a spotter
controls are in place
An outcome of unsafe practice
The reliability of material handling equipment is affected by a variety of factors:
equipment’s application dictates the ultimate reliability that can be achieved.
made the quality of repair will influence how long the machine operates before the next
There is need:
complex mining equipment.
absolute quantitative terms.
maintenance policies to enhance the operational reliability of mining operation, faults and formulate a reliability-based maintenance policy.
Testing of Safety Components
a pull wire activated device shall comply with the following requirements: a) Breaking, slackening or removal of the pull wire shall activate the device. b) Where electrical continuity is monitored in the pull wire- (i) the slackening requirements of Item (a) need not apply; and (ii) the conveyor shall stop in the event of the pull wire being broken or removed. c) The force required to operate the pull wire activated device shall not exceed 70 N when applied midway between supports and at right angles to the axis of a pull wire with less than 300mm movement and 230 N along the axis of the wire. d) The design and distance between pull wire supports shall be such that the wire moves freely when pulled and does not become disengaged from the support. NOTE: A maximum spacing of 6m should apply. e) Materials used for pull wires shall be of adequate strength, be protected against environmental conditions and be suitable for handling without the need for additional protection being worn by operators. NOTE: Where more than one switch is used in a pull wire system, a visual indicator should be provided to indicate which switch has been activated. f) The switch shall be activated when the pull wire is pulled in any direction.
Example: Pull chord Switch
Tests carried out on conveyor pull wire activated devices should ensure all requirements of Standards are taken into account.. e.g. Australian Standard AS 1755-2000
Emergency Stops The device must:
the device will not be affected by electrical or electronic circuit malfunction".
Single channel E-Stop A short to 240V (or whatever the circuit voltage is), or a faulty switch contact will render the E-Stop useless. Dual channel E-Stop without cross short detection The E-Stop filling with water or a loose wire/cable crush may short all wires within the switch together, again rendering the E-Stop useless. Dual channel E-Stop with cross short detection The safety monitoring device will detect the faults shown in figures 1 and 2 - the device is fail-safe.
Label for emergency stop devices
E-Stop that may be jammed E-Stop that cannot be jammed E-Stop contact block falls away from the button - situations such as this must be detected
Safety assurance is the application of safety engineering practices, intended to minimize the risks of operational hazards.
Reactive safety assurance Proactive safety assurance Predictive safety assurance Iterative safety assurance
Environmental safety is the practice of policies and procedures that ensure that a surrounding environment, including work areas, laboratories or facilities, is free of dangers that could cause harm to a person working in those areas. A safe place to work is the key element of environmental safety.
CONCLUSION
The process of recovery from industrial disaster surprises is disjointed, conflict ridden, long lasting and highly uncertain Responses to industrial disasters are often flawed by inaccurate perceptions
If recovery from industrial disaster surprises is to be improved, it will be necessary to acquire a more sophisticated understanding of how the process actually takes place in specific communities The post disasters measures of our mining industry during the last f decades have not yet been well publicized by the industry or by DGMS Improving recovery from events like Bhagabandh or Mahavir Colliery is an essential and feasible step in building the better capacity to manage future surprises. The more difficult task is mitigating surprises. New tools are to be tested in this regard. Fortunately, the process has started.
Providing and maintaining safe machines and systems of work for supported employees Organizing the safe use of dangerous goods and hazardous chemicals Controlling hazards such as dust, noise and fumes Providing hygiene facilities such as toilets and change rooms Providing information on hazards to ensure all supported employees have a clear understanding Providing instruction, training and supervision to supported employees Monitoring your work area and employee health Maintaining information and records on health and safety Supporting an injured supported employee’s return to work When you have some employees that need to be supported