Dgms Circular 2002

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DGMS (Tech)(SOMA) Circular No. 7 of 2002 Dhanbad, dated, the, 4. 7. 2002
To
Owner, Agent & Manager of All Coal mines.
Sub: Support of roof and side in belowground coal mines.
Roof and side fall accidents still continue to be a major cause of fatality in belowground coal
mines inspite of introduction of steel supports in such workings. An exercise was, therefore,
undertaken to analyze in detail the accidents caused by fall of roof and side during the year 2000.
Frequency distribution of all fatal accidents was carried out to identify the fatalities by major
cause group. The analysis revealed that:
1. The roof fall and side fall accidents account for 35 percent of all the fatal accidents and
63 percent of all belowground fatal accidents in coalmines.
2. Only roof fall accidents account for 26 percent of all fatal accidents in coalmines and 48
percent of all belowground fatal accidents.
3. Side fall accidents account for 9.4 percent of all fatal accidents and 14.5 percent of all
belowground fatal accidents.
The analysis further revealed that:
i. 13 percent of roof fall accidents occurred during setting of supports and 3% during
withdrawal of supports.
ii 63 percent of the roof fall accidents occurred within 10m of development and depillaring
faces i.e. in freshly exposed roof area. 33 percent of such accidents occurred in
depillaring district while 30 percent in development areas.
iii. 26 percent of the side fall accidents occurred within 10m of the working faces.
iv. All type of strata were involved in root and side fall accidents. In the roof fall accidents,
40% of the fallen strata were coal. 17% were shale, 33% sand stone and remaining were
combination of coal/shale or sand stone.
v. The thickness of the fallen strata was up to 1m in 87 percent cases of roof fall accidents.
vi. The thickness of fallen strata was up to 1m in 81 percent cases of the side fall accidents.
vii. 70 percent of roof fall accidents occurred due to inadequacy of supports in the workings.
viii. 73 percent of roof fall accidents and 81 percent of side fall accidents occurred where
gallery width was more than 4m.
ix. 84 percent of the roof fails and 64 percent of the side fall accidents occurred due to lapses
on the part of management and supervision.
x. 57 percent victims of roof fall accidents were loaders followed by 19 percent support
Crewmembers.
It is obvious from the above analysis that most of the accidents were avoidable
The analysis of the accidents, observations of the officers during inspection of mines and
interaction with support crew and subordinate supervisory officials revealed one or more of the
following deficiencies:
1 Systematic Support Rules were not being followed strictly.

2. Workmen were sometime going in-bye of the roof supports.
3. A temporary support was not provided in the freshly exposed area before engaging the
Support crew for providing permanent support.
4. Inadequate or improper examinations of roof/side manifested into roof/side falls.
5. Proper dressing of root and sides were not done prior to erection of support.
6. Support crew was not provided with proper tools I tackles
7. Safety support withdrawer was not provided and supports withdrawal was carried out by
hammering on erected supports.
8. A system of side supports was not adopted where the coal had a tendency to spall.
9. Galleries were widened excessively without any purpose.
10. Support crew was not adequately trained. Sometimes loaders and other diverted
untrained workers were engaged for bolting operation in the absence of regular support
crewmembers.
11. Rope dowels were used in place of ribbed bars.
12. Grout was not able to provide the desired anchorage of 3 tonnes and 5 tonnes after
an hours and 2 hours of setting time respectively.
13. Nuts were not compatible with respective bolts resulting into slipping of nuts over
threads.
14. Holes were not drilled in right direction and up to desired depth
15. Proper types of support materials as envisaged by tech. Circular No.3 of 1996 were not
used.
16. Bolting was not done soon after the exposure of the roof resulting into bed separation
17. A system of anchorage testing and keeping record was not in vogue.
18. Instead of random anchorage testing, pre-decided bolts were subjected to anchorage
testing.
19. A proper type of anchorage testing machine compatible with the bolts was not provided.
20. A system of monitoring of strata behaviour was not in vogue.
In the past, technical circular No.3 of 1993. Circular No.6 of 1994, Circular No.3 of 1995 and
Circular No.3 of 1996 were issued in this connection. From the above observations, it appears
that very little efforts have been made in this direction. It is, therefore, imperative that every mine
adopts a sound, safe and standard supporting procedure, a brief guideline of which is given
hereunder.
A. Scope: The procedure will detail selection of support crew members, classroom & on the
job training on setting & withdrawal of supports, roof testing, equipping them with proper tools/
tackles, making them aware of their responsibilities and adoption of a system approach to tackle
the situation, This will apply to all parts of belowground workings of every coalmine.
B. Objective- The objective is to reduce the likelihood of getting injury due to failure in
identifying hazards related to fall of roof & side.
C. Selector of persons: Persons to be newly selected to form members of the support crew
shall have a strong physique and good health to work on all man all job principle. However,
existing crewmembers having sufficient experience may continue if they are trained properly.
D. Training:
! Selected members of the support crew shall undergo initial basic training as pet
V.T. Rules and specific training modules developed for the support crew,
! They are to be a appraised of different geological disturbances viz. faults, dykes,

slips, fractured/sheared strata, ledges etc in coal mines, specially found in the
mine they are to be deployed, detailing the type and method of supports
requirements under different situations.
! They are to be appraised the significance of ringing/ drummy/ grumbling sound of

roof & support when tapped with a stick and other phenomena like development
of cracks in the roof and sides, bending or breaking of lids/props or buckling of
props, water percolation from roof etc. for any sign of weighting on supports.
! They are to, be appraised of proper method of roof testing and dressing and taking
personal protection in way of standing at safe place while testing the roof.
! They are to be appraised of systematic support rules applicable in the different

parts of the mine.
! They are to be trained in proper use of tools/ tackles for supporting the roof,
withdrawal of supports, anchorage testing etc.
! They are to be appraised the significance of providing temporary. support before

engaging themselves for erecting permanent support.
! They are to be appraised the significance of supporting the roof as soon after the
exposure of the roof as possible to prevent bed separation.
! They should be told the hazardous mechanism of roof and side fall. They are also
to be explained about the method of work being practiced in the mine.
! Sufficient number of persons shall be given training to take care of absenteeism

of the regular crewmember owing to various reasons.
! They should also be apprised of the phenomena of side spalling and method of
providing side supports.
! They should also be apprised of recommendations of safety conferences on the

subject.
E Procedure:
i. In the beginning of the shift, the support man accompanied by the Mining Sirdar
shall check and test the conventional supports in the development and depillaring
area and shall assess the requirement of additional supports to be provided during
the shift.
ii. After every round of blasting, support of roof and sides shall be tested at all
places within the zone of influence of blasting as decided by the manager.
iii. Bolting of roof shall be done as soon as possible after exposure of the roof.
iv. 9% of the bolts shall be subjected to anchorage testing for assessment of

prescribed anchorage strength and 1 percent shall be subjected to destructive
testing to assess the efficacy of support requirement and a record of such tests
shall be maintained in a bound paged register kept for the purpose in the format
as prescribed by D.Gs Technical Circular No.3 of 1996.
v. . Separate crew shall be provided for the haulage and the traveling roadways and
old workings.
vi Where the coal has a tendency to spell, the sides shall be kept supported
systematically in addition to roof supports.
F. Equipping:
As per requirement, support crew shaIl be provided with hammer, adjustable wrenches, crowbar,
suitable buntons, measuring tape, adze/ axe, pusher/stemming rod, etc. A sufficient supply of
support materials shall be ensured. Safety support withdrawal machine, anchorage testing
machine, tripods etc., shall be provided where required. Crewmembers shall also be given
personal protective equipments.
G. Responsibility: A support crew is responsible for providing proper and adequate supports
of roof and sides of the working places assigned to him. He is also responsible for checking and
resetting the old conventional supports where required and also for safe withdrawal of support
materials where required. It is needless to mention that he is also responsible for his own safety
while setting, testing and withdrawing the supports.
Sirdar and overman are responsible to ensure that entire operations of roof/side examinations,
erection/withdrawal of supports etc are carried out in a safe manner as prescribed.
Manager, Assistant Manager Under Manager are responsible for providing proper tools/ tackles
and training to the crew members and also to ensure that entire operations are carried out in a safe
manner.
H. Recommendations of the Ninth Conference on safety in mines- Recommendations of the

Ninth conference on safety in mine on coal mine supports are also reproduced below for
compliance:
Suitable type of steel/metal supports should be introduced .in all the development
districts in coalmines within two years.
Wherever practicable, roof bolting as a method of support in coal mines should be used.
Its performance should be monitored regularly. A few conventional timber props may be
used as indicator props.
Coal mining companies should take initiative to select/promote development of suitable
type of drills & other accessories for use in various types of roof strata. A task force may
be created for the purpose, which may oversee the introduction of steel supports.
Development of a portable instrument, for detecting the hidden slips in the roof of
coalmines should be taken up on priority .by R&D organizations.
(A.K Rudra.)
Director-General of Mines Safety.
DGMS/(Tech) Circular No.8 of 2002 Dhanbad, dated the 9th July, 2002.
To
The Owners, Agents and Managers
of all Mines.
Sub: Use of Protective foot wears by female workers.
It is obligatory in the part of the management of each mine that they will not allow
any person to go into or work in mine unless he/she wears a protective footwear of
approved type which shall be supplied free of charge by the mine management at
every six months.
This holds good for the female workers who are engaged in surface operation and in
quarries. Special types of foot wear as per Indian standard 11225-1985 and duly
approved by DGMS for use of female workers are available in the market.
You are once again requested to provide the above type of shoes to the female
workers as per the requirement of the statute. You are also requested to ensure that
no female workers are engaged in the mine unless she wears a protective foot wears
of the type mentioned above.
( A. K. Rudra )
Director General of Mines Safety
DGMS(Tech.)Circular No.9 of 2002 Dhanbad, dated the 9th July, 2002.
To
The Owners, Agents and Managers
of all Mines.
Sub: Calibration of environmental monitoring equipment.
You may be aware that several environmental monitoring equipments like Methanometer,
Toximeter, Oxygen monitor and multigas detectors are now being used in the coal mines for
monitoring concentration of different gases in the mine atmosphere. Whereas these instruments are
convenient in use they require careful handling and regular maintenance, which include periodic
testing for accuracy and calibration. Defective and non-calibrated equipments used for monitoring
the mine atmosphere will give incorrect and misleading results, which may create confusion during
assessment of correct environmental condition and lead to major accidents & disasters.
Recently while inspecting a degree III gassy mine it was observed the concentration of methane in
a race whe4n measured with one instrument showed 0.4% while the other of the same make
showed 4.0% in the same face. During the same inspection at another face the two instruments
indicated 0.4% & 0.1% CH4 respectively. Obviously the methanometers were not calibrated. I
need not elaborate on the consequences of such faulty measurement.
Checking the accuracy of the instruments and getting them recalibrated at regular interval would
bring out any defects in the instruments. As such I would once again like to draw immediate
attention of all concerned regarding correct and timely calibration of all monitoring equipments
and advise that the following calibration schedule be strictly adhered to :
a) Methanometers - Every 3 months.
b) Toximeter, Oxymeter - Every 3 months.
c) Multigas detector - Every 3 months.
d) All other equipments - Every 6 months.
Apart from this whenever any instrument shows maximum deflections or high readings, it shall be
immediately recalibrated.
The above instruments should be maintained and calibrated by the manufacturer/suppliers of the
instruments or their authorized agents or at an approved laboratory. A record of the above shall be
maintained showing the date and the details of maintenance and calibration.
( A. K. Rudra )
Director General of Mines Safety
DGMS (Tech.) Circular No. 10 Dated Dhanbad the 19th July, 2002.
To
Owner, Agent and Manager of all Mines.
Safe use of mobile Cranes Code of practice
A large numbers of mobile cranes are being used for material handling purposes in
most of the mine premises. A few fatal and serious accidents have been reported due
to unsafe use of such mobile cranes.
In view of the above, a code of practice for safe use of mobile cranes have been framed
based on BIS 4573 of 1982 and BIS 13367 (Part I) of 1992. The code of practice is as
follows :
1.0 Crane Safety Equipment to be provided with the Crane.
1.1 Automiatic Safe load Indicator
An automatic safe load indicator shall be provided to give warning of an

approach to the safe working load and a further warning when an overload
occurs.
1.2 Load Radius Indicator
A load radius indicator shall be provided which shall be clearly visible to the
driver and indicate the appropriate safe working load and radius for whatever
configuration of the crane is used.
1.3 Motion Limit Devices/Overload Cut Out Devices
Motion limit devices shall be provided to limit hoisting, derricking, slewing, and
boom extending or any other crane motion incase of overload or unsafe
operation.
1.4 Audio Visual Alarm during reversing
Effective Audio Visual alarm shall be provided to be actuated automatically

whenever the crane is being reversed.
1.5 Machinery Guarding
Effective guards shall be provided for gear wheels, chain drives and revolving
shafts, couplings, collars and set screws or similar moving parts, unless those
parts are made safe by design or by position or are effectively guarded by parts
of the crane structure.
1.6 Design Parameters of the mobile crane
All parameters should meet the specifications for power driven mobile crane
BIS 4573 of 1982.
1.7 Shackles and slings must conform to the relevant Indian Standard. Test
Certificates of the shackles and slings shall be maintained along with the other
crane records followed by periodical inspection.
2.0 Appointing various Competent Persons
2.1 Supervisor
The supervisor must be trained and experienced to plan the total lifting operation
safely. He shall ensure that there is an effective procedure for reporting defects
and incidents and that adequate maintenance of the equipment is carried out.
He shall be given authority to stop the operation of the crane whenever he

considers that danger is likely to arise should the operation continue.
He shall ensure that the crane is not operated in overloading situation.
2.2 Crane Driver
The Crane driver shall be responsible for the correct operation of the crane in
accordance with the manufacturers instruction book and the plan. The crane
driver shall at any one time only respond to the signals from one slinger/signaller
who should be clearly identified. He shall ensure that the crane is not operated in
overloading situation.
2.3 Slinger
The slinger is responsible for attaching and detaching the load to and from the
crane hook and the use of correct lifting gear and equipment in accordance with
planning of the operation. The slinger shall be knowledgeable enough to use the
proper sling at the proper place of the load to be lifted.
2.4 Signaller
The signaller shall be responsible for relaying the signal from the slinger to the
crane driver. The signaller may be given the responsibility for directing
movement of the crane and load instead of the slinger provided that only one
person has the responsibility. The signaller must understand the signal code.
3.0 Personal Safety Equipment
All competent person shall use safety gloves, helmet, safety spectacle, car
defenders during appropriate operation.
4.0 Access and Emergency escape
Safe means of access and emergency escape shall be provided and maintained
in good condition.
4.l For the driving position.
4.2 For Inspection, maintenance, repair, erection and dismantling of crane.
5.0 Boarding the Crane
No person shall be permitted to board a crane without first obtaining the drivers
agreement.
6.0 Fire Extinguishers
These shall be provided in all the cabins of the crane. They shall be periodically
inspected and renewed as necessary.
7.0 Record keeping
7.1 Records shall be maintained for each crane that are sufficient to enable
the condition of the crane to be determined and its fitness for further
operation to be properly assessed.
7.2. Records shall also include technical in formation including maintenance

Instructions and performance data provided by the manufacturer
7.3. Records of test certificates and all inspections of ropes and brakes shall
be maintained. All significant repairs shall also be recorded.
8.0 Proximity Hazards
Consideration shall be given to the presence of overhead electric line or

conductors, oil/gas/steam pipe lines, nearby structure etc.
Where any part of the crane of its load can not be kept clear of such
hazard, the appropriate authority should be consulted.
9.0 Periodic Checks
Supervisor must ensure that all daily, weekly and monthly checks as
recommended by the crane manufacturer are carried out and proper records be
maintained.
10.0 Other pre-requisites of the mobile crane
10.1. Different configuration of operation like On TYRE, On OUTRIGGER

shall be mentioned in the crane.
10.2. Load lifting capacity chart for different configuration like on TYRE, on
OUTRIGGER, maximum rope tension etc. shall be available with the
crane. Load lifting capacity on TYRE shall actually be much less
compared to the load lifting capacity on OUTRIGGER as can be seen
from the literatures/load charts supplied by the crane manufacturers.
11.0 Stability
11.1 Condition of tipping : The crane is considered to be at the point of tipping

when balance is reached between the overturning moment of the load and the
stabilizing moment of the machine at which point addition of any further toad
will cause imbalance
11.2 To avoid topling of crane, the operator should select correct configuration prior to
the operation of the crane like telescopic of boom, slewing of super structures,
derricking of boom, lifting of load etc.
12.0 Pick and Carry operation
Normally mobile crane should not be used as a transport equipment. However,

where pick and carry operation by the manufacturer of the crane has been
permitted, the crane driver shall not exceed the maximum recommended load
for pick and carry and he shall keep the load either at over front or over rear as
mentioned in the crane configuration and lock the slewing operation.
Minimum ground clearances shall be maintained in such cases so that

the carrying load may be guided/supported. The traveling speed of the crane
during pick and carry shall be as minimum as possible (within 1 Km to 4 Km per
hour) or as recommended during such operation by the manufacturer.
13.0 Training
The competent persons must obtain training for operation and safety in the use
of crane in consultation with the crane manufacturer.
Henceforth, the above guidelines may be strictly followed for the use
of mobile cranes in mines in the interest of safety.
( A. K. RUDRA )
Director-General of Mines Safety
DGMS (Tech)/Circular No.12 Dated, Dhanbad, the 26th, Sept., 2002
To
Owners of All
Coal, Metal and Oil Mines.
Sub Providing flash back arrestors in gas welding/cutting sets.
Investigation into a few serious accidents revealed that while using gas welding
set to cut angles or material there had been incidence of back fire which caused burn
injuries to the welders. When a back fire occurs, the products on explosion will normally
go back to the point where gases of the system get-mixed. The explosion generates
sufficient heat to explode the forward flowing gases. The phenomena happens very
rapidly and can be detected by a sharp bang followed by a high pitched scream or
whistle. Black smoke can be often seen emitting from nozzle. Flash back is actually a
back fire where so much energy can be generated that the explosion is forced back
along one of the hoses and can even burst it. Then there is the risk of explosion
passing through the regulator to cylinders with a possibility of an accident with even
fatal consequence.
In some welding sets a non-return valve had been provided as a safe guard.
However, provision of non return Valves will only ensure that the gases cannot back
feed into the system but will not stop the force generated by a flash back once it has
occurred and danger due to explosion can not be eliminated.
It is therefore recommended that flash back arrestor be provided in the gas

welding set on the oxygen and fuel gas line in the regulator side as well as Nozzle side.
ISO 5175 of 1987 (E) has dealt with Equipment used in gas welding, cutting
and allied process as safety devices for fuel gases and oxygen or compressed air

General specifications, requirements and tests.
It is necessary that the flash back arrestors so provided should conform to ISO
5175 of 1987(E) (or (lie latest version as and when published) in all respect. Such flash
back arrestors as per the above standard shall be provided with non return valve, flame
arrestor, pressure relief valve, temperature sensitive cut off valve, pressure sensitive cut
off valve and excess flow cut off valve.
The above recommendation may be complied henceforth in all gas welding and
cutting processes in the interest of safety.
(Dashrath Singh)
Chief Inspector of Mines
No.DGMS(Tech)(S&T) Circular No.13 of 2002 Dated, Dhanbad, the 31st December,2002.
To
The Owner Agent and Manager
of all mines.
Sub: Safety Management System A guideline for implementation.
Sir,
You are aware the Ninth Conference on Safety in Mines recommended to adopt Risk
Management as a tool for development of appropriate health & safety management
systems in Indian mines. It was further suggested that the risk assessment exercise
should follow an appropriate process.
The Science & Technology division of this Directorate conducted several workshops on Risk
Management in Indian mines with the assistance of experts from Australian International
Mines Safety Trai8ning Co. Pvt. Ltd., under an Indo-Australian Aid Project. Drawing inputs
from inferences drawn from the workshops and synthesizing the same with international
recommended practices, a document on Safety Management System A guideline for
implementation has been prepared and enclosed as annexure I Risk Management Plan,
designed by the officials of a coal mine is given in the Annexure-II for understanding the actual
process. This is given as guide only and need to be tailored for specific requirements.
You are requested to undertake a formal risk assessment process with the help of
above guidelines. It should be followed by preparation of Risk Management Plans
and implementation thereof, aimed at reducing the likely hood and impact of mishaps
of all kinds in Indian Mines.
Yours faithfully,
Chief Inspector of Mines
Encl: As above.
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Annexurre - I
SAFETY MANAGEMENT SYSTEM A GUIDELINE FOR
IMPLEMENTATION
BACKGROUND
Indian Mining Industry makes a major contribution to the national economy and to the
well being of the society as a whole. The countrys mineral industry represents a
unique mix of very small to medium to large mines. Currently there are 596
coalmines, 40 oil projects and a large number of non-coal mines with more than 6000
being in record under the Mines Act (however the figure is estimated to be much
larger). Besides, there are innumerable small quarries restricted to shallow depth and
employing a small number of persons that do not fall under the purview of the Mines
Act. Total workforce of the mining industry in India consists of about one million. For
the continuing viability and stability of the industry, it is important that full advantage
be taken of developments in mining methods & procedures, modern machinery &
equipments and advances in approaches to management of all mining activities,
including health & safety.
While safety in any sphere of activities is important, it has special significance when
the risk is greater. Unlike the major industries, mining has high potential risk of
accidents. It has a dubious distinction of involving a very high actual hazard as the
environment changes continually with the progress of work. It is, therefore, not
possible for any external agency to ensure safety of any mine. The principal
responsibility for the safety and good health of workers employed in mines rests with
the management of that mine.
The present day environment demands to have a fresh look at Safety Management
as a structured process composed of well defined systems that emphasises
continuous improvement in work quality, health, welfare and productivity of workforce
engaged in mineral industry through setting up of improved safety standards and
their effective implementation and administration. Because the statutory provisions
can never be fully comprehensive, appropriate and site specific and because the
process of Legislation Making is often slow, these often trail behind the technological
innovations. Trend, world over is, therefore, to make the statutory provisions
Flexible by switching over from the regime of Prescriptive Regulation to Self
Regulatory or Goal Setting Legislation. It is now widely accepted world over that the
concept of Risk management through Risk assessment contributes greatly
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towards achieving these objectives. Considering the accident scenario in Indian

Mining Industry, it has now become essential that risk assessment be undertaken of
all hazardous operations, equipment and machinery, taking account of the
procedures used, maintenance, supervision and management.
Introduction of risk management as a tool for development of good health and safety
management system is a breakthrough in the traditional strategy as it differs from the
existing one by involving the entire staff in the realization of safety improvement
programme with responsibility and accountability sharing proportionate to the
decisions making authority. The system is sure to be an effective tool for
improvement of health and safety scenario in our mining industry. The Risk
assessment process will identify all the existing and probable hazards in the work
environment and in all operations, assess the risk levels of those hazards in order to
prioritise which needs immediate attention for redressal, where maintenance of
ongoing management will be sufficient and which are of very mild nature. Then for
managing these risks, different Mechanisms (underlying causes) responsible for
these hazards are identified and their control measures, set to timetable, are
recorded pinpointing the responsibilities.
Further, the monitoring and auditing at regular interval recommended as a part of the
system would ensure that safe operating procedure are followed, evaluated,
corrected, standardised and documented training procedures for workers and
executives are in place and are carried out regularly, and commitment to health and
safety is demonstrated at all levels of organisation. On implementation of the system,
an appropriate safety level in each stage of operation may be obtained by a
systematic and documented management system with well-defined responsibility and
accountability for safety among the mine employees.
GUIDELINES FOR IMPLEMENTATION
This guideline is structured in the following way:
! Objective,
! Structure (Strategic, Management, Operations)
! Processes for Hazard Identification & Risk Assessment
! Appendices.
-3-
1 OBJECTIVE OF THE GUIDELINE
This Guideline is to assist mines put a renewed focus on managing health and safety
in their workplace.
The risk of various hazards arising in any mines ranges from almost zero to very high
depending upon the deposit being worked, the complexity & size of mining operation
as well as the conditions under which this is done and culture of the mines. Whilst
many of these are mitigated by following Standards, the aim of this Guideline is to
introduce new methods to assess and manage hazards in mines.
The Safety Management System established by a mine must ensure all risks are
identified and critical risks are controlled to ensure long-term health and safety.
A Safety Management System should set the culture, framework and actions
necessary to ensure that mining operations are carried out safely.
In order to turn these commonly agreed principals into an effective safety

management system for the mine, the system may include the following elements: -
! Health & Safety Policy of the company and the mine
! Roles and Responsibilities of all levels in the organisation
! Specified competencies of staff
! Safety Committee, formation and role
! Method to identify and control high risk
! Forward Program to ensure actions to control hazards are carried out
! Emergency Preparedness to cope with a hazard if it should occur.
! Monitoring processes for all identified hazards with or without residual risks.
! Identification of trigger points and resultant actions if these are reached.
! Safety clearance for new equipment, work methods and materials used.
! Accident Statistics collection, analysis & actions
! Reporting and record keeping Requirements
! Auditing and review processes
2 STRUCTURE OF THE SAFETY MANAGEMENT SYSTEM
The basis for ensuring safe and healthy production depends primarily on: -
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! Attitude of workforce at all levels
! Competent people
! Fit-for-purpose equipment
! Suitable work methods (or processes and procedures)
! Planned and controlled work environments
Good management will set standards to achieve these objectives and a suggested
structure for the Safety Management System is summarised below and detailed in
Sections 3 to 5.
2.1 Strategic Level
The following management strategies are required: -
! Development of organisation mission statement and policy, giving high regard

to safety and production, strongly backed by management and owners.
! Have policies made by the organisation that ensures health and safety a
critical element in all mining activities.
! Delegate organisational responsibility to appropriate levels.
! Institute formal structures and committees to discuss and implement safety

improvements.
! Establishing and maintaining the Safety Management System
2.2 Management Level
Management is responsible to follow the strategic lead of the organisation by: -
! Implementing and managing site-specific Safety Management Plans.
! Identification of major hazards and assessment of risks
! Managing hazard reduction plans.
! Defining appropriate roles and responsibilities
! Having personnel with appropriate competencies for the work
! Having site-specific emergency processes in place and tested.
! Providing appropriate guidelines, directives and training.
! Operation of formal structures and committees
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2.3 Operational Level
At operational level Managers/ Safety officers, workmen inspectors and workers

should: -
! Assess risks associated with each step of all work
! Develop and maintain a Manual outlining worksafe standards and guidelines
! Ensure personnel are trained to a competent level for each work task
! Follow safe operational processes and procedures.
! Actively participate in safety committees and continuous improvement
3 STRATEGIC LEVEL
3.1 Health & Safety Policy
The Mine Health and Safety Policy is a statement by the organisation of its
occupational health and safety philosophy and intentions. It provides a framework for
action to achieve safety objectives and targets. The Policy should: -
! Provide a mission and vision of a healthy and safe work place
! Be inclusive and understood by everybody in the mine
! Provide management commitment for: -
! A healthy and safe work place
! Regular review of risks
! Support for a Safety Management System (Safety Committee, Risk

Assessment, Continuous Improvement etc)
! Carry the expectation that mine management, supervisory staff and work
persons willingly comply with it.
3.2 Safety Management - Roles and Responsibilities
Ensuring the safety of a mining operation is a complex task requiring the continued
commitment of all personnel associated with the mine, as well as compliance with all
safety legislation, guidelines and circulars. The effective management of safety within
a mine includes the following: -
! A sound Health & Safety Policy which is supported by all sectors of the mine
! Clear roles and responsibilities of all personnel for safety
! A safety management program and forward plan
-6-
! A safe work place design for jobs, equipment and materials
! Induction, training & continuous improvement of staff
! Hazard identification and control management
! Appropriate accident and emergency plans
! Effective accident / incident investigation and reporting
! Auditing of processes and outcomes against Policy
! Review of safety management plans
In the effective management of safety, all mine personnel have different roles to play
but still have the same objective. They also share a duty of care to: -
! Provide a safe place of work
! Provide proper equipment and facilities
! Have and follow a safe system of work
! Have competent staff and employees
! Look after fellow workers
! Take appropriate precautions (eg. Use of Personal Protective Equipment)
! Raise safety issues and continuously improve
! Have appropriate emergency procedures
The roles of the following Key Staff in the Safety System should be clearly spelled
out in the safety management system as well as in all the lower levels of the plan.
Owner, Agent, Manager, Supervisor, Safety Officer, Workman Inspector, Trade

Union Representative, mechanic, operator, Worker, Contractor and Contractor
Management, etc.
3.3 Safety Committee
The Safety Committee can have a significant role in effective Mine Safety
Management. It contains representatives from all aspects of the mine, with a focus
on ensuring and improving health and safety in the workplace. Whilst the committees
function is well defined in the Mines Rules, the Safety Plan needs to outline the
operation of the Safety Committee to ensure committee members and the mines
workforce are quite clear on its role, its responsibilities and objectives.
The types of areas to clarify are: -
! The members of the Committee & their roles
! Key Responsibilities of the Committee to: -
-7-
! Improving health and safety in the workplace
! Reviewing accident / incident reports & statistics
! Identify hazards & the review of action plans
! Meeting arrangements for sub-committees, if formed
! Implementing & managing the Plan (schedule of activities)
! Reporting responsibilities and notice boards
3.4 Overall Safety Management System and Plans.
Activity Frequency Role Action

Management Annually
Set and review Mine Health & Safety (H&S) policy
Annually
Lay basis for Safety and Hazard Management Plans
Annually
Arrange for internal/external audits
Regular Annually
Review H & S policy set by Management
Health and
Safety Annually
Implement/manage Safety/Hazard Management Plans
meetings
involving Annually
Create and manage the Safety Manual
representation
across the Annually
Establish high risk areas/issues in mine for review
mine.
Annually
Set program & responsibility for the forthcoming year for
hazard review and other issues (eg. training, job
analysis, equipment assessment, etc.).
Quarterly
Review/Participate in new Hazard examinations
Monthly
Review actions completed against Action Plans; training
achievements, work procedures etc
Monthly
Review accident statistics and accident investigation,
adverse incident analysis and make appropriate
decisions
Monthly
Conduct site inspections
Monthly
Raise matters of H & S concern
Monthly
Report against Safety and Hazard Management Plan
Special
Arrange special meetings as required
-8-
4 MANAGEMENT LEVEL
4.1 Hazard Identification & Risk Management
The management of the mine should conduct a risk assessment process to identify
any hazard that could influence the safety and health of workers of the mine.
For all hazards that pose a potential chance of multiple fatalities at one time and are
not fully controlled, a Hazard Management Plan must be drawn up.
To operate mines safely all hazards must be quickly identified and controlled. Using a
risk ranking process can assist mine staff to identify the highest risk hazards for
attention. This process is summarised below and detailed in Section 7.
! Identify hazards
! Assess the risks posed by these hazards (risk ranking)
! Control or treat hazards to reduce unsafe or unhealthy situations
This technique should be used to assist effective management of safety in the

workplace within the Safety Management Plan.
It should be noted that Hazard Identification and Risk Assessment should not be
considered to be a once off occurrence but should be done at regular intervals to
ensure that the plans to cope with the identified hazards are pertinent and up to date.
4.2 Safety Management Plans.
The Safety Management Plan is a working document, which outlines all of the
actions to be carried out to ensure the safety and health at the work place. This
document is fundamental to the management of safety by the Health and Safety
Committee and Management. The sort of issues which should be addressed in the
Safety Management Plan include: -
! Important committee or safety related meeting dates
! Dates to review policies, manual or work procedures
! Dates required for major hazard analyses to be completed
! Outcomes or actions following review of hazards, accidents or statistics
! Actions, dates and responsibilities to complete agreed actions
! Achievement of actions
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4.3 Safety Manual
Accompanying the Safety Management Plan should be a Safety Manual. This

manual would outline the operational procedures to comply with the overall and
specific hazard management plans.
It is the document that would be available to all workers on site and should enable
them to be aware of not only the framework within which they have to do their work
but also what is expected from them to ensure a safe and healthy work environment.
It could contain: -
! Relevant Acts, Regulations and Circulars
! Emergency Procedures
! Standing Orders
! Individual Job Procedures
! Process for introducing new methods, equipment or materials etc.
! Training Requirements
! Hazard Identification and Risk Management Process
! Safety Management Forms (accident investigation, hazard analysis, reporting

etc.)
! Medical examinations
! Entitlements for employees injured or suffering health impacts at the mine
5 OPERATIONAL LEVEL
Operational processes and safe operating procedures need to be made to suit the
site-specific conditions of the mine. These need to be simple and clear whilst meeting
the requirements of legislation, regulations, Mine Standing Orders and recognise
Hazards associated with that work. These operating procedures must form the basis
for training and competency assessment of mine operators.
Typically, safe-operating procedures would be required for the following areas: -
! Work associated with each step of the mine production and maintenance
! Roof Support methods and rules
! Explosives transport, storage, handling and usage
! Ore handling, storage and transport
! Traffic rules and safety on haul roads
! Rules for operating equipment
-10-
! Usage of Personal Protective Equipment and critical spots in the mine for
dust, noise, heat, vibration, Illumination etc.
! Inspections, supervisions and daily reporting requirements.
! Emergencies.
! Housekeeping rules.
The safety management system should at all time be such that it promotes a process
of continuous improvement.
Because of their status and immediacy to the job, Managers and Supervisors have a
key safety role in the mine to ensure: -
! The work environment is safe for workers
! Planned work methods are safe & followed
! All accidents & near misses are investigated
! Workers are competent & know their duties
! Adequate reporting on shift change-over occur
6 HAZARD IDENTIFICATION & RISK ASSESSMENT
6.1 Definitions
Hazard: Source of potential harm, injury or loss.
Risk: combination of the likelihood of a specific unwanted event and

the potential consequences if it should occur.
Risk Assessment: Is a process that involves measurement of risk to determine

priorities and to enable identification of appropriate level of risk
treatment (used also to describe the overall process of risk
management).
Risk Control: Implementation of strategies to prevent or control hazards.
Risk Rating: The category or level or risk assigned following risk assessment
(eg. High, Medium, Low etc.)
Risk Management: Overall description of the steps taken to manage risk, by

identifying hazards and implementing controls in the workplace
-11-
6.2 Risk Assessment Process
Risk assessment is to be performed on a regular basis. The goal for each risk
assessment session is to identify hazards, determine risk ratings and controls, and to
review the implementation of risk controls from previous risk assessment sessions.
The following workflow diagram illustrates the areas involved in performing a risk
assessment session.
Assemble Identify Determine
Review Hazards Review Ranking
Determine Rank
Initiate
6.2.1 Assemble the Team
A team approach is recommended to establish hazards in the workplace. It is best to

use a vertical wedge of employees (eg. manager, engineer, safety officer, supervisor,
worker) as well as workers from different aspects of the operation to provide different
perspectives on views, likelihood, consequence and controls that are both practical
feasible and cost effective. The members of the team should be varied from session
to session to gain a broad perspective of the hazards across a site.
6.2.2 Identifying the Hazards
The process of identifying hazards is possibly the most important part of the whole
risk assessment process. This can be done in many ways but the objective is to
ensure that all of the possible hazards are identified.
Hazards are only discounted when they have been assessed not to pose a risk. Until
that is done all possible hazards should be identified and noted down.
Normally the best process is to proceed step by step through a task. A number of
other processes can also be utilised: -
! Previous experience of accidents or occurrences on the mine.
! Work process evaluation
-12-
! Consultation with employees who may have experience in the job
! Off-site specialists with experience at other mine sites (consultants).
! Fault tree analysis to determine underlying issues and hazards that might not be
evident at first glance.
! Safety statistics for this or other mines.
! Significant incident, near miss or accident reports
! Inspections in the mine
Another method is to consider the hazards that could occur from an unwanted
release of energy (eg. Mechanical, Electrical, Gravity, Fluids or air, Chemical,
Nuclear, Heat, Light, Noise)
Decide how to divide up the workplace, e.g.: -

! By activities (or processes) e.g.drilling & blasting, load and haul, crushing;
! By equipment, machinery e.g. mobile plant, trucks, conveyors, crushers;
! By geographical areas e.g. pit, compound, workshop;
! By specific job activity;
Look at specific issues and jobs. Break processes up into nodes. Examine each node
independently and look at failure modes or things that can go wrong for each node.
Examine accident-prone jobs or situations. Carry out a brainstorming exercise and
visit the site. Identify all hazards. Hazards will be identified that are likely or less
likely, have major and minor impact and importance. At this stage collect do not
exclude ideas, be defensive or squash potential hazards that are raised. Record
findings.
Notwithstanding whichever method is used for the identification of the hazards, they
should all be noted down so that a record of their existence is kept. This can be used
to save time and effort when further rounds of risk assessment are being done.
Simple forms are provided in the Appendix for use.
There should also be a mechanism for reporting of hazards by staff as they are found
which is separate from the formal risk assessment process. Hazards to be recorded
before staff forgets about potential hazards, or are not selected for the risk
assessment team.
6.2.3 Assessment of the Risk & Ranking
Objectives of risk ranking are to: -
! Identify which risks are most in need of attention, and the options for
achieving that risk reduction
-13-
! Identify which risks need careful ongoing management, the nature of the
ongoing management as well as the indicators that show that the risk is being
managed.
! Identify triggers which might be used to monitor that hazard and initiate
remedial action if elimination is not feasible
The process of Risk Ranking is carried out by considering both the Likelihood of the
occurrence of each Hazard and the potential Consequence should the Hazard occur.
Each can be estimated or calculated by engineering principles. This will enable the
risk ranking to be carried out. Risks are ranked according to the level of risk i.e. the
highest risk to the lowest risk. It is important that the risks are ranked to identify those
requiring immediate attention and maximise benefits from the efforts.
The risk of any hazard is dependent upon the chance that it will occur (likelihood) and
the impact of an occurrence (consequence): -
Risk Score = Likelihood x Consequence
Consequence is the size of the loss or damage. In terms of health and safety, it is
the degree of harm that could be caused to people exposed to the hazard, the
potential severity of injuries or ill health and / or the number of people who could be
potentially affected. It should be remembered that consequence of a hazard need not
only be in terms of safety criteria but could also be in terms of a money loss, incurred
costs, loss of production, environmental impacts as well as public outrage.
Likelihood is the chance that the hazard might occur.
In some cases personnel are only exposed to the hazard for part of the time. A more
detailed analysis can be carried out of the Risk Ranking by taking this into
consideration. Replacing Likelihood by Exposure (% time personnel are present) and
Probability (chance that they will be harmed).
Risk score = Probability x Exposure x Consequence
The values used for Likelihood, Consequence, Exposure or Probability need to be

agreed by the risk assessment team.
Risk ranking can be determined by qualitative and quantitative means. It should

however be remembered that none of these methods are best. The best choice of
method will depend on the circumstances and preferences at the mine at the time the
exercise is done. However regardless of the method establishing Risk Ranking will
set priorities for Hazard control. The most important purpose in Hazard Identification,
Risk Assessment and Ranking is to draw up and implement plans to control these
hazards. However, Keeping the acceptance of the participants during workshops
conducted at different mines, a criteria table for Quantitative Risk ranking is given in
Section 7.
These plans are then included in the Safety Management Plan.
-14-
6.2.4 Treatment Controls and Action Plans
Examine the high priority risks. Consider the potential to reduce or eliminate the risk
by using the hierarchy of controls. This assists establishing methods to reduce the
risk. From experience, the effectiveness of each method is given as a percentage
after each of the control descriptions.
Elimination: Remove step to eliminate the hazard completely ( 100% )
Substitution: Replace with less hazardous material, substance or process (75%)
Separation: Isolate hazard from person by guarding, space or time separation (50%)
Administration: Adjusting the time or conditions of risk exposures (30%)
Training: Improving skills making tasks less hazardous to persons involved (20%)
Personal protective equipment: Used as the last resort, appropriately designed

and properly fitted equipment where other controls are not practicable (5%).
Control measures can reduce either the Likelihood or Consequence of the event or
both. Depending on the level of reduction of the hazard there could still be a residual
risk that needs to be monitored so that a secondary prevention process can be
initiated when trigger points are reached.
The team should develop an action plan recommending actions, responsibilities and
when it should be completed. Put forward to decision-making authority and review if
necessary. Make a decision to proceed.
Allocate tasks, monitor progress. Review implementation effectiveness and

determine if other hazards have been created. Pursue continuous improvement.
A number of forms are included for carrying out this activity. Alternatively, the use of
software tools will enable the recording of controls and allocation of responsibility for
controls. Whichever method is used it should be formalised and controlled
periodically.
6.3 Induction, Training & Continuous Improvement
Each mine will have training programs for employees, which need to be reviewed
against safety criteria. The updating of training requirements should include re-
training of existing personnel to the new skill level. This can be performed on-the-job.
When the new skill, procedure, etc. has been taught to an individual and they have
been assessed to have achieved that Competency, this should be recorded. This
allows the mine to track staffs that are qualified to perform particular tasks. In some
instances, staff should be prevented performing tasks until they have been correctly
trained in new procedures and are considered competent to perform a task safely.
6.4 Accident / Incident Reporting & Investigation
This would be a Standing Order to ensure compliance with Regulations and to inform
mine personnel of responsibilities and reporting requirements. It should cover: -
-15-
! Responsibility of those on the site
! Immediate response and Emergency backup
! Notifying key staff of accident
! Securing the site
! Treatment of any injuries
! Investigation and Reporting
! Review of any recommendations and determining actions
6.5 Auditing & Review/Revise
Reviewing the effectiveness of programs within the Safety Management Plan. This
should be an on-going process. This should show whether policies, Regulations and
expectations are being met or where systems can be made more effective. Both
internal and external audits should be considered. Auditors need training to be
objective and independent. Management Team or the Health and Safety Committee
would have to decide how often would audits be done, what systems or areas would
be audited and reporting arrangements.
7 PROCESS
Using the equations in Section 6.2.3 the following values can be used to calculate
Risk Score for a Hazard.
Risk score = Consequence x Likelihood

Risk score = Consequence x Probability x Exposure
Scale for consequence.
Several dead 5
One dead 1
Significant chance of fatality 0.3
One permanent disability/ 0.1
less chance of fatality
Many lost time injuries 0.01
One lost time injury 0.001
Small injury 0.0001
Scale for exposure
Continuous 10
-16-
Frequent (daily) 5
Seldom (Weekly) 3
Unusual ( Monthly) 2.5
Occasional (Yearly) 2
Once in 5 years 1.5
Once in 10 years 0.5
Once in 100 years 0.02
Scale for probability
May well be expected 10

Quite possible 7
Unusual but possible 3
Only remotely possible 2
Conceivable but unlikely 1
Practically impossible 0.5
Virtually impossible 0.1
8. CONCLUSION
Management of safety issues based on assessment of risks not only integrates

safety with productivity but also can be used as a very good tool for reduction of
costs. The systems stand on the premise that all risks need not be eliminated and
different control measures can be adopted for different levels of risks. The key here
is to aim for ALARA (as low as reasonably achievable), which eventually depends on
cost considerations. The system allows prioritisation of allocation of scarce
resources thereby cutting costs and reducing wastages. This assumes great
importance in the current Indian scenario.
The other merits of the system are that it is created by the mine operators
themselves through considerable brainstorming. This approach let the mine
operators/users feel ownership of the system, something that is not cast upon hem
by experts, Govt. agencies or outsiders, and hence chances of successful
implementation is much more. In this system, grey areas are minimized;
responsibilities for action are pinpointed and scopes for auditing and improvements
are always present.
For conveniences of the mine operators different forms for risk assessment, its
control and audit is enclosed in Annexure-I. A Risk Management Plan, designed by
the officials of a coal mine is given in the Annexure-II for understanding the actual
process. This is given as guide only and need to be tailored for specific
requirements.
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DGMS (Tech)(SOMA) Circular No. 7 of 2002 Dhanbad, dated, the, 4. 7. 2002

Sub: Support of roof and side in belowground coal mines.

The analysis further revealed that:

1 Systematic Support Rules were not being followed strictly.

! They are to be a appraised of different geological disturbances viz. faults, dykes,

! They are to be appraised the significance of ringing/ drummy/ grumbling sound of

! They are to be appraised of systematic support rules applicable in the different

! They are to be appraised the significance of providing temporary. support before

! Sufficient number of persons shall be given training to take care of absenteeism

! They should also be apprised of recommendations of safety conferences on the

iv. 9% of the bolts shall be subjected to anchorage testing for assessment of

H. Recommendations of the Ninth Conference on safety in mines- Recommendations of the

Sub: Use of Protective foot wears by female workers.

DGMS(Tech.)Circular No.9 of 2002 Dhanbad, dated the 9th July, 2002.

Sub: Calibration of environmental monitoring equipment.

a) Methanometers - Every 3 months.

b) Toximeter, Oxymeter - Every 3 months.

c) Multigas detector - Every 3 months.

d) All other equipments - Every 6 months.

Safe use of mobile Cranes Code of practice

1.0 Crane Safety Equipment to be provided with the Crane.

1.1 Automiatic Safe load Indicator

An automatic safe load indicator shall be provided to give warning of an

1.2 Load Radius Indicator

1.3 Motion Limit Devices/Overload Cut Out Devices

1.4 Audio Visual Alarm during reversing

Effective Audio Visual alarm shall be provided to be actuated automatically

1.5 Machinery Guarding

1.6 Design Parameters of the mobile crane

2.0 Appointing various Competent Persons

He shall be given authority to stop the operation of the crane whenever he

He shall ensure that the crane is not operated in overloading situation.

2.2 Crane Driver

3.0 Personal Safety Equipment

defenders during appropriate operation.

4.0 Access and Emergency escape

4.l For the driving position.

4.2 For Inspection, maintenance, repair, erection and dismantling of crane.

5.0 Boarding the Crane

6.0 Fire Extinguishers

7.0 Record keeping

7.2. Records shall also include technical in formation including maintenance

8.0 Proximity Hazards

Consideration shall be given to the presence of overhead electric line or

9.0 Periodic Checks

10.0 Other pre-requisites of the mobile crane

10.1. Different configuration of operation like On TYRE, On OUTRIGGER

11.1 Condition of tipping : The crane is considered to be at the point of tipping

12.0 Pick and Carry operation

Normally mobile crane should not be used as a transport equipment. However,

Minimum ground clearances shall be maintained in such cases so that

DGMS (Tech)/Circular No.12 Dated, Dhanbad, the 26th, Sept., 2002

Sub Providing flash back arrestors in gas welding/cutting sets.

It is therefore recommended that flash back arrestor be provided in the gas

General specifications, requirements and tests.

No.DGMS(Tech)(S&T) Circular No.13 of 2002 Dated, Dhanbad, the 31st December,2002.

Sub: Safety Management System A guideline for implementation.